Articulated fluid delivery system with enhanced positioning control

ABSTRACT

A fluid delivery system including an articulated fluid delivery unit (FDU) comprising, in preferred embodiments, first and second boom sections concatenated in articulated fashion to a turret. A stinger assembly is provided at a distal end of the FDU. The stinger assembly includes a fluid connection adapter for connection to a mating fluid connection housing assembly provided on a wellhead. Independent control of rotation at each of multiple axes on the FDU allows an operator to establish a measured directional bearing at each axis, such that a set of directional bearings values defines the FDU&#39;s current spatial position. In preferred embodiments, the FDU may “learn” a desired spatial position by storing the set of directional bearings values corresponding to that spatial position. The FDU may then return to that stored spatial position robotically when instructed to recall and take up again the corresponding set of directional bearings values.

RELATED APPLICATIONS AND PRIORITY CLAIMS

This application is a continuation of co-pending, commonly-invented andcommonly-owned U.S. Nonprovisional patent application Ser. No.16/406,927 filed May 8, 2019, now U.S. Pat. No. 10,466,719. Ser. No.16/406,927 claims the benefit of and priority to the following two (2)commonly-owned co-pending U.S. Provisional Patent Applications: (1) Ser.No. 62/734,749, filed Sep. 21, 2018; and (2) Ser. No. 62/811,595, filedFeb. 28, 2019 (both now expired). Ser. No. 16/406,927 is also acontinuation-in-part of each of the following two (2) commonly-ownedco-pending U.S. Nonprovisional Patent Applications: (1) Ser. No.16/037,687, filed Jul. 17, 2018, which claims the benefit of andpriority to U.S. Provisional Patent Application Ser. No. 62/649,008,filed Mar. 28, 2018; and (2) Ser. No. 16/221,279, filed Dec. 14, 2018,which also claims the benefit of and priority to U.S. Provisional PatentApplication Ser. No. 62/649,008, filed Mar. 28, 2018. The disclosures ofthe following six (6) commonly-owned U.S. Provisional and NonprovisionalPatent Applications are further incorporated herein by reference intheir entirety: (1) Ser. No. 16/406,927, filed May 8, 2019; (2) Ser. No.62/649,008, filed Mar. 28, 2018; (3) Ser. No. 62/734,749, filed Sep. 21,2018; (4) Ser. No. 62/811,595, filed Feb. 28, 2019; (5) Ser. No.16/037,687, filed Jul. 17, 2018; and (6) Ser. No. 16/221,279, filed Dec.14, 2018.

FIELD OF THE DISCLOSURE

This disclosure relates to the field of fluid delivery, advantageouslyat high volumes and pressures, from surface-deployed equipment to wellsdrilled through subsurface formations. More particularly, in someembodiments, this disclosure relates to such fluid delivery to each of aplurality of wells having surface locations proximate each other via aremote controlled delivery system.

BACKGROUND

Wells drilled through subsurface formations are used for, among otherpurposes, extracting useful fluids such as oil and gas. Some subsurfaceformations are treated (“stimulated”) by pumping fluid under pressureinto such formations for the purpose of creating, propagating andpropping open networks of fractures to enhance extraction of oil andgas. This technique is commonly known as “fracking”. It is known in theart to drill wells for fracking substantially along the geologictrajectory of certain subsurface formations, while drilling a pluralityof such “directional” or “lateral” wells from proximate surfacelocations. U.S. Patent Application Publication No. 2011/0030963 filed byDemong et al. (“Demong”) discloses an exemplary arrangement of wellshaving proximate surface locations. Demong also describes controlledfluid pumping and valve equipment enabling selective opening of one ormore wells to (1) fracking fluid delivery into selected wells or (2)flow from the subsurface formation to the surface.

Demong's background disclosure provides a useful general discussion ofat least some aspects of the state of the current art. Demong'sbackground is also applicable background to the technology described inthis disclosure. The following background discussion includesadaptations of Demong's background disclosure where applicable to thisdisclosure.

During typical fracking operations, fluid is pumped into the formationat pressures that exceed the fracture pressure of the formations. Thefractures in the formation thus opened up may be held open by pumping ofmaterial (proppant) that supports the fracture structurally after thefluid pressure on the formation is relieved. Other fluid treatments mayinclude, for example, pumping acid into the wellbore to dissolve certainminerals present in the pore spaces of the formations that reduce theformation permeability.

Wellbores may be drilled into hydrocarbon-bearing formations alongdirected trajectories that may deviate from vertical. In land-basedfracking deployments, such deviated wellbores may be drilled, forexample, so that the surface locations of the wellbores are closelyspaced on a relatively small land area called a “pad”, while thelowermost portions of the wellbore extend laterally from the respectivesurface locations in a selected drainage pattern. Such arrangementreduces or minimizes the amount of land surface affected by the frackingoperations.

Conventionally, fracking operations on multiple wells drilled from acommon surface pad typically require multiple connections anddisconnections in order to (1) connect the pumping equipmenthydraulically to one well, (2) pump the fluid, then (3) disconnect thepumping equipment from the well before another well can be fluidtreated. Such conventional piping configurations often involve layingpipe from each fracking fluid delivery truck to a central collectionmanifold and then in single or multiple lines to the well being treated.The result is that a costly separate rig-up and rig down is required forevery fracture treatment. Such operations can create, among otherexposures, safety risks to personnel working on or near the pad orplatform, and interference with the operation of wellbores that areproducing oil and/or gas while the fluid treatment equipment isconnected and disconnected from various wellbores on the pad orplatform. Such connection and disconnection operations may also takeconsiderable amounts of time to perform.

FIG. 1 illustrates “zipper fracking”, a conventional (prior art)approach to optimizing the multiple pipe connections describedimmediately above. On FIG. 1, pumping units 10 deliver fluid at pressureinto manifold M1. Pumping units 10 may be conventional fracking pump anddelivery trucks such as illustrated on FIG. 1. Manifold M1 may be knowncolloquially as a “missile” in some embodiments. Fluid transfer lines 20on FIG. 1 deliver fluid from manifold M1 to manifold M2. Manifold M2 maybe known colloquially as a “zipper frack” in some embodiments. ManifoldM2 provides a plurality of control outputs 30. Control outputs 30 areeach connected by one or more fluid delivery pipes to a “goat head”style manifold 40 atop a wellhead W. In oilfield fracking and wellcompletion parlance, “goat head” refers to a style of manifold with ahollow body providing multiple fluid line connection points (e.g. flangefaces).

Fluid delivery to wellheads W on FIG. 1 is controlled by actuation ofcontrol valves on control outputs 30. Advantageously, flow through eachfluid delivery pipe connecting a control output 30 to a correspondinggoat head 40 is independently controlled by a separate control valve. Inthis way, an operator may actuate different control valves at differenttimes to deliver fluid from manifold M2 to selected wellheads W asdesired.

The drawbacks of “zipper fracking” according to FIG. 1 include that thesetup is very inefficient in use of hardware such as control outputs 30and corresponding control valves. The setup of FIG. 1 calls forconsiderable hardware spending its time idle. Likewise, the laborrequired for setup and teardown is high, since each control output 30requires multiple fluid delivery pipes to be physically connected andthen disconnected from a goat head 40.

FIG. 2 illustrates another conventional (prior art) approach todelivering fracking fluid to a wellhead. Crane truck CT is positionednearby a wellhead W into which fluid is desired to be delivered. Crane Con crane truck CT advantageously provides telescoping boom TB. As shownon FIG. 2, crane C and telescoping boom TB bring wellhead connector WCnearby wellhead W. A first operator, also nearby wellhead W, thenmanhandles wellhead connector WC onto wellhead W as wellhead connectorWC hangs suspended from telescoping boom TB. Meanwhile, a secondoperator (not illustrated on FIG. 2) assists by making adjustments tothe suspended position of wellhead connector WC via operation of crane Cand telescoping boom TB.

Once the first operator has secured wellhead connector WC to wellhead W,piping P on crane truck CT may be connected to fracking fluid atoperating pressures and delivery volumes. Fluid delivery to wellhead Wmay commence.

At the completion of fluid delivery, fluid flow through piping P isterminated, and the first operator may disconnect wellhead connector WCfrom wellhead W. The second operator then actuates crane C andtelescoping boom TB to move wellhead connector WC towards a secondwellhead W in range to be connected in the same manner as the first.Alternatively, the second operator moves wellhead connector WC ontocrane truck CT with crane C. Crane truck CT may then be physicallyrelocated to a position nearby a new wellhead W to be serviced.

There are several drawbacks to prior art fluid delivery according toFIG. 2. There are operator safety issues, particularly with the firstoperator required to manhandle wellhead connector WC onto wellhead W.The operation also optimally requires two operators. The operators mustbe skilled. Depending on local conditions and the skill level of theoperators, manual connection of wellhead connector WC onto wellhead maybe slow and imprecise. It is also likely that only a small number ofwellheads W will be in range of crane truck CT without need forphysically relocating crane truck CT.

There is therefore a need in the art for an improved fluid connectionand delivery system for multiple wellheads that can reduce the amount ofand complexity of conduit between fluid apparatus and selected wellheadsin a multiple well system. Such an improved fluid delivery system willadvantageously reduce risks to operating personnel safety. Embodimentsof such an improved fluid delivery system will further optimize fluiddelivery in high-pressure, high-volume fracking operations. Suchoptimizations will advantageously include automated and robotic controlover spatial positioning of the fluid delivery system with respect towellheads to be serviced.

SUMMARY AND TECHNICAL ADVANTAGES

These and other needs in the prior art are addressed by a fluid deliverysystem including an articulated fluid delivery unit (FDU) comprising, inpreferred embodiments, a first boom section concatenated in articulatedfashion to a turret, and a second boom section concatenated inarticulated fashion to the first boom section. The turret rotates abouta generally vertical axis. A stinger assembly is provided at a distalend of the second boom section. The stinger assembly includes a fluidconnection adapter for connection to a mating fluid connection housingassembly provided on a wellhead. The stinger assembly includes rotatingconnections allowing independent rotation (or tilting) of the fluidconnection adapter. In preferred embodiments, the stinger assemblyprovides two (2) such rotating connections configured to rotate inorthogonal planes.

Control over spatial positioning of the FDU is enabled by rotationalcontrol at multiple axes of rotation at corresponding articulating orrotating connections on board the FDU. In preferred embodiments, thereare five (5) independently-controlled axes of rotation: turret, firstboom section to turret, second boom section to first boom section,stinger assembly to second boom section and second orthogonal rotationat stinger assembly. Independent control of rotation at each of theseaxes allows an operator to establish a measured directional bearing ateach axis, such that a set of values for all directional bearings at agiven time defines the FDU's current spatial position. In preferredembodiments, the FDU may “learn” a desired spatial position (e.g., withthe fluid connection adapter positioned immediately above a desiredwellhead) by storing the set of directional bearings valuescorresponding to that spatial position. The FDU may then return to thatspatial position robotically in the future when instructed to recall andtake up again the corresponding set of directional bearings values. [Theterm “robotic” or “robotically” as used in this disclosure is intendedto mean, consistent with plain English usage, that the FDU takes actionas a machine capable of carrying out a series of actions by itself,responsive to instructions from a source such as a software routine].

In preferred embodiments, control over FDU's spatial position is byremote control. In such embodiments, a user directs movement of the FDUvia a wirelessly-connected hand-held controller. In some embodiments,the controller may also store and recall sets of directional bearingsvalues corresponding to spatial positions that the user directs the FDUto “learn”.

In preferred embodiments, the FDU delivers fluid to its destination viafluid-bearing piping and fittings connected to articulating or rotatingcomponents such as the turret, the first and second boom sections andthe stinger assembly. The fluid-bearing piping and fittings include afluid inlet, a plurality of swivel joints and a fluid connection adapterall in fluid flow communication. The swivel joints facilitate FDUarticulation and rotation. Currently preferred embodiments of the FDUare designed for fracking fluid delivery service, in which the FDU isasked to deliver fracking fluid at operating pressures of not less thanabout 7,500 psi (“ksi”), and more preferably not less than about 10,000psi (“10 ksi”), and yet more preferably not less than about 15,000 psi(“15 ksi”), all at delivery volumes requiring a 7″ or 8″ internaldiameter (“ID”) pipe. As described in more detail in this disclosure,designing a serviceable 7″-8″ ID swivel joint rated for 15 ksi workingpressure has proved challenging. Commercially-available swivel jointsrated for 15 ksi service are typically available in sizes up to 4″ IDonly and will not deliver the volume of fluid required for frackingoperations. Larger ID commercially-available swivel joints have provenunable to withstand the tensile stresses imparted by 15 ksi workingpressure. Thus, in preferred embodiments, each swivel joint has aninternal diameter of not less than about 7 inches. Further, each swiveljoint is preferably capable of retaining an internal pressure of notless than about 7,500 psi (“7.5 ksi”), and more preferably capable ofrotation while retaining an internal pressure of not less than about 7.5ksi. More preferably, each swivel joint is preferably capable ofretaining an internal pressure of not less than about 10,000 psi (“10ksi”), and more preferably capable of rotation while retaining aninternal pressure of not less than about 10 ksi. Yet more preferably,each swivel joint is capable of retaining an internal pressure of notless than about 15 ksi, and more preferably capable of rotation whileretaining an internal pressure of not less than about 15 ksi.

FDU embodiments according to this disclosure include two swivel jointembodiments whose designs have been specifically engineered and testedto withstand internal working pressures of 15 ksi with ID at least 7″.Significant effort and investment has been made to solve a problem andmeet a need in this regard that the prior art appeared neither torecognize or address. As described in more detail further below, thedisclosure of co-pending, commonly-assigned U.S. Provisional PatentApplication Ser. No. 62/811,595, filed Feb. 28, 2019, incorporatedherein by reference, describes at least one previous swivel joint designthat was engineered, tested and then rejected as unable to withstand aninternal working pressure of 15 ksi with an ID of at least 7″. Rejectionof this previous design was a precursor to designing the swivel jointembodiments disclosed herein.

It is therefore a technical advantage of the disclosed fluid deliverysystem to deliver fluid to a desired delivery destination (such as awellhead) quickly, efficiently, safely and precisely. Once the FDU hasbeen physically positioned in a desired jobsite location, FDUembodiments including stored and recalled spatial positioning allowrepeated deliveries to wellheads whose spatial position the FDU has“learned”. The FDU can further make quick, safe and precise and safereturns to wellheads that have previously received fluid.

A further technical advantage of the disclosed fluid delivery system isthat in some embodiments, a first inclinometer is provided on the FDUsuperstructure or chassis. This first inclinometer may measure,quantitatively, the degree to which the FDU stands “out of level” in itscurrent jobsite position. In FDU embodiments including stored andrecalled spatial positioning, “out of level” information from the firstinclinometer may correct sets of directional bearings data measured ataxes of rotation.

A further technical advantage of the disclosed fluid delivery system isthat in some embodiments, a second inclinometer is provided on thestinger assembly to maintain the fluid connection adapter in a constantplumb vertical attitude during motion of the FDU. This secondinclinometer may measure, quantitatively, the degree to which the fluidconnection adapter is currently “out of plumb vertical” during othermotion of the FDU. In some FDU embodiments, “out of plumb vertical”information from the second inclinometer may direct the FDU to makeautomated adjustments to maintain the fluid connection adapter in aconstant plumb vertical attitude regardless of the current motion ofother FDU components. This feature facilitates, for example, entry ofthe fluid connection adapter into the fluid connection housing assemblyat the wellhead.

A further technical advantage of the disclosed fluid delivery system isthat it may be remotely operable in preferred embodiments.

A further technical advantage of the disclosed fluid delivery system isthat it embodiments include swivel joints specifically designed for thehigh operating pressures and fluid flow volumes demanded by fracturingfluid delivery service.

A further technical advantage of the disclosed fluid delivery system isthat, in currently preferred embodiments, fluid-bearing piping andfittings include swivel joint embodiments rated for fracking fluiddelivery working pressures and delivery volumes. Swivel jointembodiments disclosed herein also allow rotation under operatingpressure. Rotation under pressure allows small positional adjustments tobe made to the FDU 100 “on the fly” during fluid delivery to a wellhead.The ability to make small positional adjustments “on the fly” maintainscontinuous fluid flow during such adjustments, thereby allowing, forexample, “on the fly” compensation for fluid surges or vibration. Incontrast, comparative swivel joints in the prior art are known torequire positional (rotational) locking while under operating pressure,and especially while fluid is being delivered to a wellhead. Thus, ifthe operator does not position the fluid delivery system precisely priorto beginning fluid delivery to a well, fluid delivery may have to beinterrupted later on if small positional adjustments need to be made.

A further technical advantage of the disclosed fluid delivery system isthat in some embodiments, wall thickness monitoring is provided tomonitor wall thickness of delivery piping and fittings in locations atrisk of loss of wall thickness during service.

A further technical advantage of the disclosed fluid delivery system isthat some embodiments may provide an integrated nightcap capability. Insuch embodiments, a nightcap is stored on the stinger assembly. Morepreferably, the nightcap is positioned longitudinally opposed to thefluid connection adapter on the stinger assembly. In such embodiments,the nightcap assumes a rest position pointing generally upwards whilethe fluid connection adapter is pointing generally downwards ready forfluid delivery to a wellhead. When the nightcap is desired to bedeployed, a user may rotate the stinger assembly so that the nightcapand the fluid connection adapter are inverted. The nightcap is now inposition to be inserted into a wellhead.

A further technical advantage of the disclosed fluid delivery system isthat its design favors robustness and dependability. Embodiments of thedisclosed fluid delivery system minimize moving parts and hydraulics inorder to enhance robustness at high pressures in larger diameters.

In accordance with a first aspect, therefore, this disclosure describesembodiments of a fluid delivery system including a fluid delivery unit(FDU), the FDU comprising: a turret and a stinger assembly separated byfirst and second boom sections in which the boom sections areconcatenated via a rotatable connection; a fluid inlet; a fluidconnection adapter deployed on the stinger assembly; and a plurality ofswivel joints, such that the fluid inlet, the swivel joints and thefluid connection adapter are in fluid flow communication; wherein: (1)each boom section has a turret end and a stinger end; (2) the turret endof the first boom section is rotatably connected to the turret; and (3)the stinger end of the second boom section is rotatably connected to thestinger assembly; wherein rotation of the turret defines rotation aboutan axis A1 on a directional bearing B1; wherein rotation of the turretend of the first boom section about the turret defines rotation about anaxis A2 on a directional bearing B2; wherein rotation of the turret endof the second boom section about the stinger end of the first boomsection defines rotation about an axis A3 on a corresponding directionalbearing B3; wherein rotation of the stinger assembly about the stingerend of the second boom section defines rotation about an axis A4 on acorresponding directional bearing B4; wherein the stinger assembly isfurther configured to rotate about an axis A5 on a correspondingdirectional bearing B5; wherein the FDU further includes a plurality ofrotary encoders R[1 . . . 5], one rotary encoder deployed at each of acorresponding one of axes A[1 . . . 5] such that each rotary encoder isconfigured to measure a corresponding one of directional bearings B[1 .. . 5] to establish sets of measured bearings values B_(VAL)[1 . . . 5],wherein sets of B_(VAL)[1 . . . 5] define corresponding spatialpositions for the FDU; wherein the FDU is configured to store and recallsets of B_(VAL)[1 . . . 5]; wherein the FDU is further configured torobotically take up a corresponding spatial position when directed torecall a previously-stored set of B_(VAL)[1 . . . 5].

In embodiments according to the first aspect, rotation about axis A5 isin an orthogonal plane to rotation about axis A4.

In embodiments according to the first aspect, a controller isconfigured, via wireless communication, to allow a user to perform atleast one activity selected from the group consisting of: (a) actuatingrotation about selected ones of axes A[1 . . . 5]; (b) deploying anightcap positioned on the stinger assembly; and (c) storing andrecalling sets of B_(VAL)[1 . . . 5].

In embodiments according to the first aspect, a first inclinometer isconfigured to correct sets of B_(VAL)[1 . . . 5] for the FDU being outof out of level.

In embodiments according to the first aspect, a second inclinometer isconfigured to maintain the fluid connection adapter in a constant plumbvertical attitude during motion of the FDU.

In embodiments according to the first aspect, at least one swivel jointincludes: a first elbow, an annular lip formed on the first elbow, afirst housing piece received over the first elbow and retained by theannular lip, a second elbow, an exterior threaded pin surface formed onthe second elbow, a second housing piece received over the second elbow;a swivel collet, wherein swivel collet threads on the swivel colletthreadably engage with the threaded pin surface such that the secondhousing piece is retained by the swivel collet; first and second rotarybearings separated by the swivel collet such that the first housingpiece is received over the second rotary bearing and the second housingpiece is received over the first rotary bearing, wherein rigidconnection of the first and second housing pieces allows independentdifferential rotation between the first and second elbows about thefirst and second rotary bearings.

In embodiments according to the first aspect, at least one swivel jointincludes: a first elbow, an annular lip formed on the first elbow, afirst housing piece received over the first elbow and retained by theannular lip; an integral pin, an annular rib formed on a proximal end ofthe integral pin, a second housing piece received over the integral pinand retained by the annular rib; first and second rotary bearingsseparated by the annular rib such that the first housing piece isreceived over the second rotary bearing and the second housing piece isreceived over the first rotary bearing, wherein rigid connection of thefirst and second housing pieces allows independent differential rotationbetween the first elbow and the integral pin about the first and secondrotary bearings. In some embodiments, a second elbow is rigidlyconnected to a distal end of the integral pin.

In some embodiments according to the first aspect, a slew drive isconfigured to actuate rotation about at least one of axes A[1 . . . 5].In other embodiments according to the first aspect, a piston isconfigured actuate at least one of axes A[1 . . . 5].

In accordance with a second aspect, this disclosure describesembodiments of a fluid delivery system including a fluid delivery unit(FDU), the FDU comprising: a turret and a stinger assembly separated byfirst and second boom sections in which the boom sections areconcatenated via a rotatable connection; a fluid inlet; a fluidconnection adapter deployed on the stinger assembly; and a plurality ofswivel joints, each swivel joint having an internal diameter of not lessthan about 7 inches, each swivel joint further capable of rotation whileretaining an internal pressure of not less than about 10,000 psi;wherein the fluid inlet, the swivel joints and the fluid connectionadapter are in fluid flow communication; wherein: (1) each boom sectionhas a turret end and a stinger end; (2) the turret end of the first boomsection is rotatably connected to the turret; and (3) the stinger end ofthe second boom section is rotatably connected to the stinger assembly;wherein rotation of the turret defines rotation about an axis A1 on adirectional bearing B1; wherein rotation of the turret end of the firstboom section about the turret defines rotation about an axis A2 on adirectional bearing B2; wherein rotation of the turret end of the secondboom section about the stinger end of the first boom section definesrotation about an axis A3 on a corresponding directional bearing B3;wherein rotation of the stinger assembly about the stinger end of thesecond boom section defines rotation about an axis A4 on a correspondingdirectional bearing B4; wherein the stinger assembly is furtherconfigured to rotate about an axis A5 on a corresponding directionalbearing B5; wherein the FDU further includes a plurality of rotaryencoders R[1 . . . 5], one rotary encoder deployed at each of acorresponding one of axes A[1 . . . 5] such that each rotary encoder isconfigured to measure a corresponding one of directional bearings B[1 .. . 5] to establish sets of measured bearings values B_(VAL)[1 . . . 5],wherein sets of B_(VAL)[1 . . . 5] define corresponding spatialpositions for the FDU; wherein the FDU is configured to store and recallsets of B_(VAL)[1 . . . 5]; wherein the FDU is further configured torobotically take up a corresponding spatial position when directed torecall a previously-stored set of B_(VAL)[1 . . . 5].

In embodiments according to the second aspect, rotation about axis A5 isin an orthogonal plane to rotation about axis A4.

In embodiments according to the second aspect, a controller isconfigured, via wireless communication, to allow a user to perform atleast one activity selected from the group consisting of: (a) actuatingrotation about selected ones of axes A[1 . . . 5]; (b) deploying anightcap positioned on the stinger assembly; and (c) storing andrecalling sets of B_(VAL)[1 . . . 5].

In embodiments according to the second aspect, a first inclinometer isconfigured to correct sets of B_(VAL)[1 . . . 5] for the FDU being outof out of level.

In embodiments according to the second aspect, a second inclinometer isconfigured to maintain the fluid connection adapter in a constant plumbvertical attitude during motion of the FDU.

In embodiments according to the second aspect, at least one swivel jointincludes: a first elbow, an annular lip formed on the first elbow, afirst housing piece received over the first elbow and retained by theannular lip; a second elbow, an exterior threaded pin surface formed onthe second elbow, a second housing piece received over the second elbow;a swivel collet, wherein swivel collet threads on the swivel colletthreadably engage with the threaded pin surface such that the secondhousing piece is retained by the swivel collet; first and second rotarybearings separated by the swivel collet such that the first housingpiece is received over the second rotary bearing and the second housingpiece is received over the first rotary bearing, wherein rigidconnection of the first and second housing pieces allows independentdifferential rotation between the first and second elbows about thefirst and second rotary bearings.

In embodiments according to the second aspect, at least one swivel jointincludes: a first elbow, an annular lip formed on the first elbow, afirst housing piece received over the first elbow and retained by theannular lip, an integral pin, an annular rib formed on a proximal end ofthe integral pin, a second housing piece received over the integral pinand retained by the annular rib; first and second rotary bearingsseparated by the annular rib such that the first housing piece isreceived over the second rotary bearing and the second housing piece isreceived over the first rotary bearing, wherein rigid connection of thefirst and second housing pieces allows independent differential rotationbetween the first elbow and the integral pin about the first and secondrotary bearings. In such embodiments, a second elbow is rigidlyconnected to a distal end of the integral pin.

In accordance with a third aspect, this disclosure describes embodimentsof a fluid delivery system including a fluid delivery unit (FDU), theFDU comprising: a turret and a stinger assembly separated by a pluralityof concatenated boom sections S[1 . . . N] in which adjacent boomsections are connected via rotatable connections; a fluid inlet; a fluidconnection adapter deployed on the stinger assembly; a plurality ofswivel joints, such that the fluid inlet, the swivel joints and thefluid connection adapter are in fluid flow communication; wherein: (1)each boom section has a turret end and a stinger end; (2) the turret endof boom section S[1] is rotatably connected to the turret; (3) thestinger end of one boom section S[1 . . . N−1] is rotatably connected tothe turret end of an adjacent boom section S[2 . . . N]; and (4) thestinger end of boom section S[N] is rotatably connected to the stingerassembly; wherein rotation of the turret defines rotation about an axisA[1] on a directional bearing B[1]; wherein rotation of the turret endof boom section S[1] about the turret defines rotation about an axisA[2] on a directional bearing B[2]; wherein rotation of the turret endof one boom section S[2 . . . N] about the stinger end of an adjacentboom section S[1 . . . N−1] defines rotation about a corresponding axisA[3 . . . N+1] on a corresponding directional bearing B[3 . . . N+1];wherein rotation of the stinger assembly about the stinger end of boomsection S[N] defines rotation about an axis A[N+2] on a correspondingdirectional bearing B[N+2]; wherein the stinger assembly is furtherconfigured to rotate about Q additional rotational axes A[N+3 . . .N+2+Q] each on a corresponding directional bearing B[N+3 . . . N+2+Q];wherein the FDU further includes a plurality of rotary encoders R[1 . .. N+2+Q], one rotary encoder deployed at each of a corresponding one ofaxes A[1 . . . N+2+Q] such that each rotary encoder is configured tomeasure a corresponding one of directional bearings B[1 . . . N+2+Q] toestablish sets of measured directional bearings values B_(V)A[1 . . .N+2+Q], wherein sets of B_(VAL)[1 . . . N+2+Q] define correspondingspatial positions for the FDU; wherein the FDU is configured to storeand recall sets of B_(VAL)[1 . . . N+2+Q]; wherein the FDU is furtherconfigured to robotically take up a corresponding spatial position whendirected to recall a previously-stored set of B_(VAL)[1 . . . N+2+Q].

In embodiments according to the third aspect, rotation about one of axesA[N+3 . . . N+2+Q] is in an orthogonal plane to rotation about axisA[N+2].

In embodiments according to the third aspect, a controller isconfigured, via wireless communication, to allow a user to perform atleast one activity selected from the group consisting of: (a) actuatingrotation about selected ones of axes A[1 . . . N+2+Q]; (b) deploying anightcap positioned on the stinger assembly, and (c) storing andrecalling sets of B_(VAL)[1 . . . N+2+Q].

In embodiments according to the third aspect, a first inclinometercorrects sets of B_(VAL)[1 . . . N+2+Q] for the FDU being out of out oflevel.

In embodiments according to the third aspect, a second inclinometermaintains the fluid connection adapter in a constant plumb verticalattitude during motion of the FDU.

In embodiments according to the third aspect, at least one swivel jointincludes: a first elbow, an annular lip formed on the first elbow, afirst housing piece received over the first elbow and retained by theannular lip, a second elbow, an exterior threaded pin surface formed onthe second elbow, a second housing piece received over the second elbow;a swivel collet, wherein swivel collet threads on the swivel colletthreadably engage with the threaded pin surface such that the secondhousing piece is retained by the swivel collet; first and second rotarybearings separated by the swivel collet such that the first housingpiece is received over the second rotary bearing and the second housingpiece is received over the first rotary bearing, wherein rigidconnection of the first and second housing pieces allows independentdifferential rotation between the first and second elbows about thefirst and second rotary bearings.

In embodiments according to the third aspect, at least one swivel jointincludes: a first elbow, an annular lip formed on the first elbow, afirst housing piece received over the first elbow and retained by theannular lip; an integral pin, an annular rib formed on a proximal end ofthe integral pin, a second housing piece received over the integral pinand retained by the annular rib; first and second rotary bearingsseparated by the annular rib such that the first housing piece isreceived over the second rotary bearing and the second housing piece isreceived over the first rotary bearing, wherein rigid connection of thefirst and second housing pieces allows independent differential rotationbetween the first elbow and the integral pin about the first and secondrotary bearings. In such embodiments, a second elbow is rigidlyconnected to a distal end of the integral pin.

In some embodiments according to the third aspect, a slew drive isconfigured to actuate rotation about at least one of axes A[1 . . .N+2+Q]. In other embodiments according to the third aspect, a piston isconfigured actuate at least one of axes A[1 . . . N+2+Q].

In accordance with a fourth aspect, this disclosure describesembodiments of a fluid delivery system including a fluid delivery unit(FDU), the FDU comprising: a turret and a stinger assembly separated bya plurality of concatenated boom sections S[1 . . . N] in which adjacentboom sections are connected via rotatable connections; a fluid inlet; afluid connection adapter deployed on the stinger assembly; a pluralityof swivel joints, such that the fluid inlet, the swivel joints and thefluid connection adapter are in fluid flow communication; wherein: (1)each boom section has a turret end and a stinger end; (2) the turret endof boom section S[1] is rotatably connected to the turret; (3) thestinger end of one boom section S[1 . . . N−1] is rotatably connected tothe turret end of an adjacent boom section S[2 . . . N]; and (4) thestinger end of boom section S[N] is rotatably connected to the stingerassembly; wherein rotation of the turret defines rotation about an axisA[1] on a directional bearing B[1]; wherein rotation of the turret endof boom section S[1] about the turret defines rotation about an axisA[2] on a directional bearing B[2]; wherein rotation of the turret endof one boom section S[2 . . . N] about the stinger end of an adjacentboom section S[1 . . . N−1] defines rotation about a corresponding axisA[3 . . . N+1] on a corresponding directional bearing B[3 . . . N+1];wherein rotation of the stinger assembly about the stinger end of boomsection S[N] defines rotation about an axis A[N+2] on a correspondingdirectional bearing B[N+2]; wherein the FDU further includes a pluralityof rotary encoders R[1 . . . N+2], one rotary encoder deployed at eachof a corresponding one of axes A[1 . . . N+2] such that each rotaryencoder is configured to measure a corresponding one of directionalbearings B[1 . . . N+2] to establish sets of measured directionalbearings values B_(VAL)[1 . . . N+2], wherein sets of B_(VAL)[ . . .N+2] define corresponding spatial positions for the FDU; wherein the FDUis configured to store and recall sets of B_(VAL)[1 . . . N+2]; whereinthe FDU is further configured to robotically take up a correspondingspatial position when directed to recall a previously-stored set ofB_(VAL)[1 . . . N+2].

In embodiments according to the fourth aspect, a controller isconfigured, via wireless communication, to allow a user to perform atleast one activity selected from the group consisting of: (a) actuatingrotation about selected ones of axes A[1 . . . N+2]; (b) deploying anightcap positioned on the stinger assembly; and (c) storing andrecalling sets of B_(VAL)[1 . . . N+2].

The foregoing has outlined rather broadly some of the features andtechnical advantages of the technology embodied in the disclosed fluiddelivery system technology, in order that the detailed description thatfollows may be better understood. Additional features and advantages ofthe disclosed technology may be described. It should be appreciated bythose skilled in the art that the conception and the specificembodiments disclosed may be readily utilized as a basis for modifyingor designing other structures for carrying out the same inventivepurposes of the disclosed technology, and that these equivalentconstructions do not depart from the spirit and scope of the technologyas described and as set forth in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of embodiments described in detailbelow, and the advantages thereof, reference is now made to thefollowing drawings, in which:

FIG. 1 illustrates one prior art arrangement for delivery of fluid toselected wellheads;

FIG. 2 illustrates another prior art arrangement for delivery of fluidto a selected wellhead;

FIG. 3 illustrates an embodiment of Fluid Delivery Unit (FDU) 100delivering fluid to selected wellheads in accordance with thisdisclosure;

FIG. 4 further illustrates an embodiment of Fluid Delivery Unit (FDU)100 delivering fluid to selected wellheads in accordance with thisdisclosure;

FIG. 5 is an elevation view of an embodiment of FDU 100 according tothis disclosure;

FIG. 6 is a perspective view of spatial positioning of FDU 100embodiments according this disclosure, illustrating rotation axes A1through A5 on which corresponding directional bearings B1 through B5 maybe selected;

FIG. 7 is a further perspective view of an embodiment of FDU 100according to this disclosure, in which spatial positioning and otheraspects of FDU 100 are under control of controller 200;

FIG. 8 illustrates a currently preferred embodiment of controller 200;

FIG. 9 illustrates, in isolation, a currently preferred layout ofconnected fluid-bearing piping and fittings on board an embodiment ofFDU 100 according to this disclosure;

FIG. 10 is an enlarged view as shown on FIG. 9;

FIGS. 11A, 11B and 11C illustrate assembled, section and exploded viewsrespectively of swivel joint embodiment 500A;

FIGS. 12A, 12B and 12C illustrate assembled, section and exploded viewsrespectively of swivel joint embodiment 500B;

FIG. 13A illustrates currently preferred embodiments of stinger assembly600 in detail, and of nightcap 1000 generally;

FIG. 13B is a section as shown on FIG. 13A;

FIG. 13C is an exploded view of FIG. 13A;

FIGS. 14A, 14B and 14C illustrate a currently preferred embodiment ofnightcap 1000 and its associated features; and

FIG. 15 is a schematic generally illustrating wall thickness monitoringaccording to this disclosure.

DETAILED DESCRIPTION

The following description of embodiments provides non-limitingrepresentative examples using Figures and schematics with part numbersand other notation to describe features and teachings of differentaspects of the disclosed technology in more detail. The embodimentsdescribed should be recognized as capable of implementation separately,or in combination, with other embodiments from the description of theembodiments. A person of ordinary skill in the art reviewing thedescription of embodiments will be capable of learning and understandingthe different described aspects of the technology. The description ofembodiments should facilitate understanding of the technology to such anextent that other implementations and embodiments, although notspecifically covered but within the understanding of a person of skillin the art having read the description of embodiments, would beunderstood to be consistent with an application of the disclosedtechnology.

FIGS. 1 and 2 of this disclosure illustrate examples of the prior art onwhich the disclosed technology seeks to improve. FIGS. 1 and 2 arediscussed in detail above in the “Background” section.

FIGS. 3 through 15 of this disclosure illustrate currently preferredembodiments of the disclosed fluid delivery system technology. For thepurposes of the following disclosure, FIGS. 3 through 15 should beviewed together. Any part, item, or feature that is identified by partnumber on one of FIGS. 3 through 15 will have the same part number whenillustrated on another of FIGS. 3 through 15. It will be understood thatthe embodiments as illustrated and described with respect to FIGS. 3through 15 are exemplary only and serve to illustrate the larger conceptof the technology. The inventive material set forth in this disclosureis not limited to such illustrated and described embodiments.

Fluid Delivery Unit (FDU) 100

FIGS. 3 and 4 illustrate an embodiment of Fluid Delivery Unit (FDU) 100delivering fluid to selected wellheads W1 through W4 in accordance withthis disclosure. FIG. 3 is a general plan drawing, and FIG. 4 is ageneral perspective drawing, each illustrating a currently preferredembodiment of FDU 100 in an exemplary jobsite deployment. FIG. 5 is anelevation view of an embodiment of FDU 100 by itself. FIGS. 6 and 7 areperspective views illustrating currently preferred embodiments ofspatial positioning of the FDU 100 embodiment of FIG. 5. Spatialpositioning is described in detail in a separate section of thisdisclosure further below. FIG. 9 illustrates, in isolation, a currentlypreferred layout of connected fluid-bearing piping and fittings on boardthe FDU 100 embodiment of FIG. 5. Generally, FIG. 9 depicts suchfluid-bearing piping and fittings including a fluid inlet 106, aplurality of swivel joints 500A, 500B and a fluid connection adapter 900all in fluid flow communication. FIG. 10 is an enlarged view as shown onFIG. 9.

FIGS. 3 and 4 illustrate FDU 100 deployed on site via truck trailer T.Deployment on truck trailer T is currently preferred for convenience inbringing FDU 100 to a desired location. However, the scope of thisdisclosure is not limited to the manner by which FDU 100 is deployed onsite. FIGS. 3 and 4 (and especially FIG. 4) further illustrate FDU 100deployed to deliver fluid (such as fracking fluid) to selected wellheadsW1 through W4 within reach of FDU 100. Again, the scope of thisdisclosure is not limited to fracking fluid delivery service. FDU 100may also be deployed in other applications for which it is suited.

It will be appreciated from FIGS. 3 and 4 that FDU 100 is disposed todeliver fluid anywhere within its range. Depiction on FIGS. 3 and 4 ofdelivery to a selected one of wellheads W1 through W4 is forillustrative convenience only. Currently preferred embodiments of FDU100 include rotating base turret 102 which, as may be seen on FIG. 4,enables FDU 100 to deliver fluid anywhere within range on a 360-degreerotation of turret 102. For more examples of possible fluid deliveryranges for some embodiments, see FIG. 4B and associated disclosure ofco-pending, commonly-assigned U.S. Provisional Patent Application Ser.No. 62/811,595, filed Feb. 28, 2019 (the disclosure of which provisionalapplication is incorporated herein by reference). It will nonetheless beunderstood that fluid delivery ranges illustrated on FIGS. 3 and 4hereof, and on FIG. 4B of Ser. No. 62/811,595 are exemplary only andthat the scope of this disclosure is not limited to such illustratedfluid delivery ranges. Further, both smaller scale and larger scaleembodiments of FDU 100 are within the scope hereof.

FIG. 3 shows FDU 100 receiving fluid ultimately from pumping units 10.As with the prior art depiction of FIG. 1, pumping units 10 may beconventional fracking pump and delivery trucks (as illustrated),although the scope of this disclosure is indifferent to the manner bywhich fluid is ultimately made available to FDU 100. On FIG. 3, pumpingunits 10 deliver fluid at pressure into manifold M1. Again as with theprior art depiction of FIG. 1, manifold M1 may be known colloquially asa “missile” in some embodiments. Fluid transfer lines 20 on FIG. 3deliver fluid from manifold M1 to FDU fluid inlet 106. Seen more clearlyon FIGS. 5, 6 and 7, the illustrated embodiment of FDU fluid inlet 106may be of the manifold style commonly referred to as a “goat head” inoilfield fracking and well completion operations, with a hollow bodyproviding multiple connection points (e.g. flange faces) to connect toindividual fluid transfer lines 20. In the embodiment illustrated onFIG. 3 through FIG. 7, up to seven (7) fluid transfer lines 20 may beconnected to FDU fluid inlet 106 for delivery of fluid by FDU 100 toselected wells within reach of FDU 100. It will nonetheless beappreciated that FDU fluid inlet 106 as illustrated on FIG. 3 throughFIG. 7 is exemplary only, and other non-illustrated embodiments mayprovide more or fewer supply lines. The scope of this disclosure is notlimited to any particular design of FDU fluid inlet 106. Moreover,although not illustrated, additional fluid pressure (e.g. via additionalpumping) may be provided in some embodiments between manifold M1 and FDUinlet manifold 106. Such additional fluid pressure, if required, helpsensure FDU 100 is receiving fluid for delivering to wellheads at desiredservice pressures and flow rates/volumes.

FIG. 4 illustrates FDU 100 providing stinger assembly 600 at a distaldelivery end thereof. Stinger assembly 600 is described in greaterdetail below in a separate section of this disclosure. However, FIG. 4depicts stinger assembly 600 including fluid connection adapter 900.FIG. 4 also shows each wellhead W1 through W4 disposed to receive fluidvia a fluid connection housing assembly 950 connected to the topthereof. Fluid connection housing assemblies 950 are advantageouslyalike in that fluid connection adapter 900 on stinger assembly 600 isconfigured to be received and locked into any one of a desired fluidconnection housing assembly 950 prior to delivery of fluid to acorresponding wellhead W1 through W4.

Currently preferred embodiments of fluid connection adapter 900 andfluid connection housing assembly 950 are consistent with embodimentsdescribed in the following commonly-assigned disclosures, all of whichare incorporated herein by reference: U.S. Provisional PatentApplication Ser. No. 62/649,008 filed Mar. 28, 2018; U.S. Nonprovisionalpatent application Ser. No. 16/037,687 filed Jul. 17, 2018; and U.S.Nonprovisional patent application Ser. No. 16/221,279 filed Dec. 14,2018 (collectively the “Preferred Fluid Connection Designs”). It will benonetheless understood that although currently preferred embodimentsdeploy fluid connection adapter 900 and fluid connection housingassembly 950 consistent with the Preferred Fluid Connection Designs, thescope of this disclosure is not limited to any particular design ofconnection between stinger assembly 600 and wellheads W1 through W4.

FIG. 5 is an elevation view of an embodiment of FDU 100 according tothis disclosure. As described above with respect to FIGS. 3 and 4, FIG.5 shows FDU 100 preferably deployed on site via truck trailer T,although the scope if this disclosure is not limited in this regard. Theembodiment of FDU 100 on FIG. 5 provides FDU superstructure 101 rigidlyattached to truck trailer T. As shown on FIGS. 4 and 5, FDUsuperstructure 101 provides conventional outriggers OR for stabilizingand leveling FDU 100. In other embodiments, outriggers OR may beconnected to truck trailer T. The scope of this disclosure is notlimited to the manner in which FDU 100 may be stabilized and leveled.Conventional hydraulic controls may actuate and manipulate outriggers ORto set FDU 100 in stable and level fashion on the local terrain.

FDU 100 on FIG. 5 further includes rotating base turret 102. Turret 102is disposed to rotate about FDU superstructure 101. As previouslydescribed with reference to FIG. 4, preferred embodiments of turret 102enable FDU 100 to deliver fluid anywhere within range on a 360-degreerotation of turret 102. FIG. 5 further depicts first boom section 103and second boom section 104. First and second boom sections 103, 104 areconcatenated via a rotatable connection to be further described below.First boom section 103 has a turret end 103T and a stinger end 103S(referring to stinger assembly 600, also shown on FIG. 5). Second boomsection 104 also has a turret end 104T and a stinger end 104S. Turretend 103T of first boom section 103 is rotatably connected to turret 102as described further below with reference to FIG. 6. As shown on FIG. 5,rotation of first boom section 103 about turret 102 is actuated byextension and retraction of first boom piston 105A. Stinger end 103S offirst boom section 103 connects to turret end 104T of second boomsection 104 also via a rotating connection described further below withreference to FIG. 6. As shown on FIG. 5, rotation of second boom section104 about first boom section 103 is actuated by extension and retractionof second boom piston 105B. Stinger end 104S of second boom section 104is rotatably connected to stinger assembly 600 also as described furtherbelow with reference to FIG. 6 and FIGS. 13A, 13B and 13C. Actuation ofrotation of stinger assembly 600 about second boom section 104 isdescribed in detail further below in a separate section of thisdisclosure.

It will therefore be appreciated from FIG. 5 that first and second boomsections 103, 104 on FDU 100 are articulated boom sections connected viarotating connections whose independent rotation allows FDU 100 to deploystinger assembly 600 (and fluid connection adapter 900) to reach andconnect to selected wellheads within range. Preferred embodiments, asillustrated, provide two (2) concatenated boom sections 103, 104. Thescope of this disclosure is not limited, however, to two (2)concatenated boom sections 103, 104, and other embodiments (notillustrated) may deploy more or fewer concatenated articulated boomsections.

In preferred embodiments illustrated and described with reference toFIGS. 7 and 8, operators may use remote-controlled spatial positioningto rotate turret 102 and extend/retract boom sections 103, 104 in orderto deploy stinger assembly 600 (and fluid connection adapter 900) toreach and connect to selected wellheads within range. Such spatialpositioning is described in detail further below in a separate sectionof this disclosure. In other embodiments (not illustrated), conventionalhydraulic controls may enable user-operated rotation of turret 102 anduser-operated extension/retraction of boom section 103, 104 as requiredto deploy stinger assembly 600 (and fluid connection adapter 900) toreach and connect to selected wellheads within range. The scope of thisdisclosure is not limited to a particular mode of user control.

FIG. 9 illustrates, in isolation, a currently preferred layout ofconnected fluid-bearing piping and fittings on board the FDU 100embodiment of FIG. 5. FIG. 10 is an enlarged view as shown on FIG. 9.FIGS. 9 and 10 depict FDU fluid inlet 106 connected by fluid-bearingpiping and fittings all the way to fluid connection adapter 900 onstinger assembly 600. Fluid-bearing piping and fittings include swiveljoint embodiments 500A, 500B as further described below with referenceto FIGS. 11A through 11C and FIGS. 12A through 12C. Currently preferredembodiments of swivel joints 500A, 500B are described in detail below ina separate section of this disclosure. Fluid-bearing piping and fittingson FIGS. 9 and 10 further include union assemblies 300 and clampassemblies 400. Currently preferred embodiments of union assemblies 300are further described below with reference to FIGS. 11A through 11C.Currently preferred embodiments of clamp assemblies 400 are furtherdescribed below with reference to FIGS. 12A through 12C. Fluid-bearingpiping and fittings on FIGS. 9 and 10 further include delivery piping120 and conventional fittings 130 such as standard elbows.

It will be appreciated that the scope of this disclosure is not limitedto the currently preferred layout of fluid-bearing piping and fittingsillustrated on FIGS. 9 and 10. The layout illustrated on FIGS. 9 and 10is configured for the embodiment of FDU 100 on FIG. 5, which itself isan exemplary embodiment of FDU 100. The layout of fluid-bearing pipingand fittings on a particular FDU 100 embodiment will depend on thedesign of the FDU 100 embodiment.

It will be further appreciated that the scope of this disclosureincludes embodiments in which FDU does not just deliver fluid from asource to a wellhead W. The scope of this disclosure also includesnon-illustrated embodiments in which FDU delivers fluid from a wellheadW to a desired destination.

In other, non-illustrated embodiments, fluid-bearing piping could berouted inside boom sections rather than on the side of the boom section.

Swivel Joint Embodiments 500 and 500B

As has been previously noted, currently preferred embodiments of FDU 100according to this disclosure are designed for delivery of fracking fluidto wellheads. In some FDU 100 embodiments designed for fracking service,fluid-bearing piping and fittings are designed for 7,500 psi (“7.5 ksi”)internal fluid pressures (plus an appropriate factor of safety), andmore preferably for 10 ksi internal fluid pressures (plus an appropriatefactor of safety), and yet more preferably for 15 ksi internal fluidpressures (plus an appropriate factor of safety). Such FDU 100embodiments designed for fracking service further deliver fluid volumessuitable for fracking operations downhole. Such fluid delivery volumestypically necessitate a 7″-8″ internal diameter (“ID”).

Designing a 7″-8″ ID swivel joint rated for 15 ksi working pressure hasproved challenging. Commercially-available swivel joints rated for 15ksi service are typically available in sizes up to 4″ ID only. Swiveljoints with 4″ ID will not deliver the volume of fluid required forfracking operations. Larger ID commercially-available swivel joints haveproven unable to withstand the tensile stresses imparted by 15 ksiworking pressure. It will be understood that increasing the diameter ofthe swivel joint while maintaining the operating pressure increasesgeometrically the tension static load force exerted by the pressure atthe ID circumference. Such static load forces act to “break apart” theswivel joint at its outer circumference.

As a result, several custom designs have been proposed, designed andtested with Finite Element Analysis (FEA) to arrive at a suitable designfor swivel joint embodiments 500A, 500B as described herein for frackingfluid delivery service. The disclosure of U.S. Provisional PatentApplication Ser. No. 62/811,595, filed Feb. 28, 2019, incorporatedherein by reference, describes a previous design PD1 that had to berejected for use with fracking fluid delivery service because the FEAindicated that PD1 would likely fail under load if asked to deliver thevolume of fracking fluid required at 15 ksi operating pressure.

FIGS. 11A through 12C of this disclosure illustrate two swivel jointembodiments 500A and 500B engineered to be suitable for the currentlypreferred fracking fluid delivery embodiments of FDU 100 described inthis disclosure. Differences generally between swivel joint embodiments500A and 500B include that swivel joint embodiment 500A is a pin andcollet design, whereas swivel joint embodiment 500B is an integral pindesign.

Swivel joint embodiments 500A and 500B, as described and illustratedherein, are the result of a subsequent, refined design of swivel jointthat FEA indicated would perform under load if asked to deliver thevolume of fracking fluid required at 15 ksi operating pressure.Embodiments of swivel joints 500A, 500B were originally selected at 8″ID in order to be sure to enable FDU 100 to deliver fluid at requiredvolumes. FEA demonstrated that although a performing design inaccordance with swivel joints 500A and 500B above was available, this 8″ID design created an undesirably heavy fluid-bearing piping and fittingslayout for FDU 100.

Design then moved to a 7″ ID for swivel joint embodiments 500A, 500B,with an associated design change to 7″ ID fluid-bearing piping andfittings layout on FDU 100. It was determined that a 7″ ID assemblywould also deliver an acceptable volume of fracking fluid at anoperating pressure of 15 ksi. Migrating to a 7″ design brought severaltechnical advantages over the 8″ design: (a) lower overall weight offluid-bearing piping and fittings layout; (b) wider commercialavailability of standard parts such as delivery pipe, flanges andelbows; and (c) higher margin of safety at 15 ksi operating pressure.With regard to the higher margin of safety, FEA showed that the 7″embodiment would hold up to 1.9 million lbs force static load at thecircumference, well exceeding the goal of 1.3 million lbs force staticload for 15 ksi rated operating pressure.

Referring now to U.S. Provisional Patent Application Ser. No. 62/811,595(“'595”), filed Feb. 28, 2019, incorporated herein by reference, FIGS.8A and 8B of '595 depict FEA results for 7′ ID embodiments of swiveljoints 500A and 500B respectively from FIGS. 11A through 12C in thisdisclosure. FIG. 8C of '595 depicts a further FEA chart for a 7″ IDembodiment of swivel joint 500B from FIGS. 12A through 12C of thisdisclosure. As can be seen on FIGS. 8A through 8C of '595, FEAdetermined that 7″ ID embodiments of swivel joints 500A and 500B wouldperform under load if asked to deliver the volume of fracking fluidrequired at 15 ksi operating pressure.

Swivel joint embodiments 500A, 500B on FIGS. 11A through 12C also allowrotation under operating pressure. This feature is yet a furthertechnical advantage over known prior art swivels in fracking service.Swivel joint embodiments 500A, 500B allow such rotation under pressureeven while fluid is being delivered to a wellhead. Rotation underpressure in turn allows small positional adjustments to be made to FDU100 “on the fly” during fracking fluid delivery to a wellhead. Theability to make small positional adjustments “on the fly” maintainscontinuous fluid flow during such adjustments, and further reducesstresses on FDU 100 and its components.

In contrast, comparative swivel joints in the prior art are known torequire positional (rotational) locking while under operating pressure,and especially while fluid is being delivered to a wellhead. If, as inthe prior art, the swivel joints are locked during fluid delivery, thedelivery system is prevented from making small positional adjustments tosuit environmental conditions during delivery, such as, for example, tocompensate for small displacements due to fluid surges or vibration.Thus, in the prior art, if the operator does not position the fluiddelivery system precisely prior to beginning fluid delivery to a well,fluid delivery may have to be interrupted later on if small positionaladjustments need to be made. Fluid delivery will have to be stopped tounlock the swivels so that positional adjustment can be made. Further,even if positional adjustments are not needed, the boom components maybe unnecessarily stressed with locked swivels if initial positioning isimprecise.

FIG. 11A depicts an exterior view of swivel joint embodiment 500A asfully assembled. FIG. 11B is a section as shown on FIG. 11A. FIG. 11C isan exploded view of FIG. 11A. Looking at FIGS. 11A, 11B and 11Ctogether, swivel joint embodiment 500A includes first elbow 501 with anannular lip 502 formed on a proximal end thereof. When swivel joint 500Ais assembled (refer FIGS. 11A and 11B), first housing piece 503 isreceived over first elbow 501 and is retained by annular lip 502.

With further reference to FIGS. 11A, 11B and 11C together, first andsecond housing pieces 503, 506 receive rotary bearings 504A and 504Bseparated by swivel collet 505. Rotary bearings 504A, 504B will bedescribed in more detail below. Second elbow 508 has exterior threadedpin surface 509 and exterior seal groove 512 formed on a proximal endthereof. Second housing piece 506 is received over second elbow 508.Swivel collet 505 has internal swivel collet threads 511 such that, whenswivel collet threads are threadably engaged with exterior threaded pinsurface 509 on second elbow 508, second housing piece 506 and rotarybearing 504A are retained by swivel collet 505, and second housing piece506 is received over rotary bearing 504A. Rotary bearing 504B isreceived on the other side of swivel collet 505 from rotary bearing504A, and first housing piece 503 is received over rotary bearing 504B.First and second housing pieces 503, 506 are rigidly connected togetherwith fasteners 507. As fasteners 507 connect first and second housingpieces 503 and 506, exterior seal groove 512 on second elbow 508 isreceived into annular lip 502 on first elbow 501. Seal ring 513, asreceived into exterior seal groove 512, forms a rotating seal betweenfirst and second elbows 501, 508 while still allowing independentdifferential rotation between first and second elbows 501, 508 withinswivel joint embodiment 500A.

Looking further now at FIGS. 11A, 11B and 11C together, union assemblies300 are depicted at the distal ends of each of first and second elbows501, 508. Union assemblies 300 are preferably alike throughout thisdisclosure, and are formed by union collet 302 received into union nut301. Union nut 301 is then threadably received onto a first fitting(e.g. first or second elbows 501, 508 per FIGS. 11A, 11B and 11C) viathreaded engagement between union nut threads 304 and fitting threads303 on the first fitting. At the same time, union collet 302 isthreadably received onto a second fitting (e.g. one end of fluidconnection adapter 900 or one end of a piece of delivery piping 120 perFIGS. 13A, 13B and 13C)) via threaded engagement between union colletthreads 305 and mating threads provided on the end of the secondfitting. Preferably the threaded engagement between union collet 302 andthe second fitting is via a left hand thread, while the threadedengagement between union nut 301 and the first fitting is via aconventional right hand thread. In this way, when union nut 301 istightened down on the first fitting, tightening rotation of the threadedengagement between union nut 301 and the first fitting will also causetightening of the threaded engagement between union collet 302 and thesecond fitting.

FIG. 12A depicts an exterior view of swivel joint embodiment 500B asfully assembled. FIG. 12B is a section as shown on FIG. 12A. FIG. 12C isan exploded view of FIG. 12A. Looking at FIGS. 12A, 12B and 12Ctogether, swivel joint embodiment 500B includes first elbow 521 with anannular lip 522 provided on a proximal end thereof. When swivel joint500B is assembled (refer FIGS. 12A and 12B), first housing piece 523 isreceived over first elbow 521 and is retained by annular lip 522.

With further reference to FIGS. 12A, 12B and 12C together, first andsecond housing pieces 523, 526 receive rotary bearings 524A and 524Bsuch that rotary bearings 524A, 524B are separated by annular rib 531formed on a proximal end of integral pin 525. Rotary bearings 524A, 524Bwill be described in more detail below. Integral pin 525 provides firstand second bearing contact surfaces 528, 529 either side of annular rib531. Rotary bearing 524A is received onto second bearing contact surface529, and rotary bearing 524B is received onto first bearing contactsurface 528. Second housing piece 526 is received over rotary bearing524A and integral pin 525. First and second housing pieces 523, 526 arerigidly connected together with fasteners 527. Integral pin 525 also hasexterior seal groove 532 provided on the proximal end thereof. Asfasteners 527 connect first and second housing pieces 523 and 526,exterior seal groove 532 on integral pin 525 is received into annularlip 522 on first elbow 521. Seal ring 533 as received into exterior sealgroove 532 forms a rotatable seal between integral pin 525 and firstelbow 521 while still allowing independent differential rotation betweenintegral pin 525 and first elbow 521 within swivel joint embodiment500B.

FIGS. 12A, 12B and 12C each further depict clamp assembly 400 rigidlyconnecting a distal end of integral pin 525 to a proximal end of secondelbow 536. Clamp assemblies 400 are preferably alike throughout thisdisclosure. Clamp assembly 400 includes an annular fitting lip 404 andan annular fitting groove 405 each provided on a proximal end of afitting to be clamped to integral pin 525 (e.g. on a proximal end ofsecond elbow 536 per FIGS. 12A, 12B and 12C). First clamp housing piece401 is received into fitting groove 405. Second clamp housing piece 403is received over the distal end of integral pin 525. Clamp collet 402provides internal clamp collet threads 407. Clamp collet 402 rigidlyaffixes to the distal end of integral pin 525 via threaded engagement ofclamp collet threads 407 with integral pin threads 406 provided on thedistal end of integral pin 525. The distal end of integral pin 525 isthen received into fitting lip 404 such that when first and second clamphousing pieces 401, 403 are rigidly connected with fasteners 408,fitting lip 404 bears down tightly on clamp collet 402. Sealing betweenintegral pin 525 and fitting lip 404 may be provided by conventionalo-ring seals or the like.

With further reference to FIGS. 12A, 12B and 12C, it will be understoodthat clamp assembly 400 is provided to ensure that torque is transmittedinto swivel joint embodiment 500B through integral pin 525, so thatswivel joint 500B may allow independent differential rotation betweenfirst and second elbows 521, 536. By contrast with swivel jointembodiment 500A on FIGS. 11A, 11B and 11C, clamp assembly 400 is notneeded on swivel joint embodiment 500A since second elbow 508 transmitstorque directly into swivel joint 500A via threaded engagement withswivel collet 505, thereby allowing independent differential rotationbetween first and second elbows 501, 508.

Looking further now at FIGS. 12A, 12B and 12C together, union assemblies300 are depicted at the distal ends of each of first and second elbows521, 536. Union assemblies 300 are preferably alike throughout thisdisclosure, and are described above in detail with reference to FIGS.11A, 11B and 11C.

Rotary Bearings Embodiments in Swivel Joint Embodiments 500A and 500B

Currently preferred embodiments of rotary bearings 504A, 504B, 524A,524B are illustrated in exploded form on FIGS. 11C and 12C. It will beunderstood that such illustrated embodiments are exemplary only, andthat the scope of this disclosure is not limited to the currentlypreferred rotary bearings embodiments illustrated on FIGS. 11C and 12C.Currently preferred embodiments of rotary bearings 504A, 504B, 524A,524B are annular thrust bearings, in which a rotary bearing assembly isformed by providing cylindrical roller bearings spaced radially inpockets around an annular plate (cage). The “caged” assembly is thenitself interposed between two annular thrust plates (raceways), oneabove and one below, so that the cylindrical roller bearings in thebearing assembly bear against and roll against the annular thrust platesabove and below. Suitable embodiments of rotary bearings 504A, 504B,524A, 524B as illustrated on FIGS. 11C and 12C may include productsavailable from The Timken Company of North Canton, Ohio, U.S.A., withcurrent preference for model 100TP143. Timken advertises this design tobe particularly suited to manage high radial loads even whenmisalignment, poor lubrication, contamination, extreme speeds orcritical application stresses are present. As currently advertised byTimken: “Type TP thrust cylindrical roller bearings have two hardenedand ground raceways and a window-type steel cage which retains one ormore profiled rollers per pocket. When multiple rollers are used in eachpocket, they are different lengths and are placed in staggered positionrelative to rollers in adjacent pockets to create overlapping rollerpaths. This minimizes wear of the raceways and therefore increasesbearing life. Because of the simplicity of their design, type TPbearings are economical.” As noted, however, the scope of thisdisclosure is not limited to the above-described style of rotarybearings or to Timken® models.

Spatial Positioning of Fluid Delivery Unit (FDU) 100

FIGS. 6 and 7 depict spatial positioning aspects as deployed oncurrently preferred embodiments of FDU 100. As depicted on FIGS. 6 and7, spatial positioning is a mode of user-operated remote control of FDU100, in which, for example, fluid connection adapter 900 at a distal endof FDU 100 may be directed to be received into fluid connection housingassembly 950 on a desired target wellhead W_(T). It will be understoodthat spatial positioning of FDU 100 under guidance of remote control isan optional feature in accordance with this disclosure. Otherembodiments may provide FDU 100 without the remote-controlled spatialpositioning feature, in which case FDU 100 may be operated andpositioned via conventional manual hydraulic controls. The scope of thisdisclosure is not limited to FDU 100 embodiments that deployremote-controlled spatial positioning.

Focusing momentarily on currently preferred FDU 100 embodiments thatdeploy remote-controlled spatial positioning, FIG. 7 shows thatcurrently preferred FDU 100 embodiments deploy remote user operation viaa remotely-operated controller 200 communicating wirelessly with FDU100. FIG. 7 illustrates how the user of such a remotely-operatedcontroller 200 may stand in a safe area that allows good visibility oftarget wellhead W_(T), facilitating precise connection between fluidconnection adapter 900 and fluid connection housing assembly 950 viaremote control operation of FDU 100.

Such wireless communication may preferably be via radio frequencycommunication RF as shown on FIG. 7, although the scope of thisdisclosure is not limited in this regard. FIG. 8 depicts one exemplaryembodiment of controller 200, as shown generally on FIG. 7. FIG. 8'sembodiment of controller 200 is described below in detail in a separatesection of this disclosure. It will be nonetheless understood that thescope of this disclosure includes many different embodiments ofcontroller 200 on FIG. 7 (including different layouts, features, modesand functionalities).

It will be further understood that FDU 100 embodiments that deployspatial positioning are not limited to user operation via remotecontrol. In other embodiments (not illustrated), may provide spatialpositioning controls (including different layouts, features, modes andfunctionalities) deployed directly on truck trailer T or FDUsuperstructure 101, for example.

Referring now to FIG. 6, currently preferred embodiments of FDU 100provide axes of rotation A1 through A5. As described elsewhere ingreater detail in this disclosure, a slew drive is configured to actuaterotation about at least one of axes A[1 . . . 5], and a piston isconfigured to actuate rotation about at least one of axes A[1 . . . 5].Rotation about axes A1 through A5 are defined as follows in suchpreferred embodiments:

A1—Rotation of turret 102 about FDU superstructure 101 (vertical axis);A2—Rotation of turret end 103T of first boom section 103 about turret102 (horizontal axis);A3—Rotation of turret end 104T of second boom section 104 about stingerend 103S of first boom section 103 (horizontal axis);A4—Rotation of stinger assembly 600 about stinger end 104S of secondboom section 104 (horizontal axis); andA5—Further rotation of stinger assembly 600 (horizontal axis).

It will be appreciated that axes of rotation A4 and A5 are in orthogonalplanes to one another. In this way, according to the embodimentillustrated on FIG. 6, rotation of FDU 100 components about axes A1though A5 bring about the following motions of fluid connection adapter900 with respect to fluid connection housing assembly 950 on targetwellhead W_(T):

A1—Set target azimuth for fluid connection adapter 900 towards targetwellhead W_(T)A2—Elevate/lower and extend/retract fluid connection adapter 900 alongtarget azimuthA3—Further elevate/lower and extend/retract fluid connection adapter 900along target azimuthA4—Rotate (tilt) fluid connection adapter 900 in parallel plane totarget azimuthA5—Rotate (tilt) fluid connection adapter 900 in orthogonal plane totarget azimuth

It will be thus seen with reference to FIG. 6 that establishment of adirectional bearing B1 through B5 on each of a corresponding one of axesA1 through A5 will collectively define a point in space for fluidconnection adapter 900 within FDU 100's reach. It therefore follows thata set of values B_(VAL)[1 . . . 5] ascribed to each of directionalbearings B1 through B5 will define the current spatial position for FDU100, and in particular for fluid connection adapter 900. It furtherfollows that a different set of values B_(VAL)[1 . . . 5] ascribed toeach of directional bearings B1 through B5 will define a correspondingspatial position for a target for fluid connection adapter 900 on FIG.6, such as fluid connection housing assembly 950 on target wellheadW_(T).

Illustrated embodiments of FDU 100 further include a plurality of rotaryencoders R1 through R5, one rotary encoder deployed at each of acorresponding one of axes A1 through A5, such that each rotary encoderis configured to measure a corresponding one of directional bearings B1through B5 to establish sets of measured bearings values B_(VAL)[1 . . .5]. As described immediately above, sets of B_(VAL)[1 . . . 5] definecorresponding spatial positions for FDU 100. Looking now at FIG. 7alongside FIG. 6, FIG. 7 illustrates rotary encoders R1 through R3provided at each of a corresponding one of axes A1 through A3. Rotaryencoders R1 through R3 measure current values B_(VAL)[1 . . . 3] ofdirectional bearings B1 through B3 at each of a corresponding one ofaxes A1 through A3. It will be understood that stinger assembly 600 onFIG. 7 provides rotary encoders R4 and R5 at axes A4 and A5,respectively, for measurement of current values B_(VAL)[4, 5] ofdirectional bearings B4 and B5, respectively. Rotary encoders R4, R5 areomitted for clarity on FIG. 7, but are illustrated on FIGS. 13A, 13B and13C, for example. FIGS. 13A, 13B and 13C illustrate stinger assembly 600in more detail. This disclosure describes stinger assembly 600(including rotary encoders R4, R5 as shown on FIGS. 13A, 13B and 13C) indetail further below in a separate section. Suitable embodiments ofrotary encoders R1 through R5 may include products available from Turck,Inc. of Minneapolis, Minn., U.S.A., although the scope of thisdisclosure is not limited in this regard.

FIG. 7 also illustrates currently preferred FDU 100 embodiments in whichturret slew drive 110 is deployed on FDU superstructure 101. Turret slewdrive 110 rotates turret 102. Turret slew drive 110 is conventional inpreferred embodiments, in which at least one spur gear is provided toengage and drive annular gears on turret 102 so as rotate turret 102about axis A1. FIG. 7 depicts rotary encoder R1 deployed in associationwith turret slew drive 110 as is also known in the art. Rotary encoderR1 measures a current rotational position for turret 102 about axis A1so as to establish a current directional bearing B1 about axis A1.Rotary encoder R1 then transmits the current directional bearing B1 inreal time to storage, memory and/or a data processing unit as a dataelement used in overall control of FDU 100.

Rotary encoder R2 on FIG. 7 measures rotation at axis A2 so as toestablish a current directional bearing B2 at axis A2. It will berecalled from earlier disclosure with respect to FIG. 5 that turret 102connects rotatably to turret end 103T of first boom section 103 toestablish axis A2. FIG. 7 shows that extension and retraction of firstboom piston 105A actuates rotation about axis A2. Rotary encoder R2measures a current rotational position for first boom section 103 aboutaxis A2 so as to establish a current directional bearing B2 about axisA2. Rotary encoder R2 then transmits the current directional bearing B2in real time to storage, memory and/or a data processing unit as a dataelement used in overall control of FDU 100.

Rotary encoder R3 on FIG. 7 measures rotation at axis A3 so as toestablish a current directional bearing B3 at axis A3. It will berecalled from earlier disclosure with respect to FIG. 5 that stinger end103S of first boom section 103 connects to turret end 104T of secondboom section 104 to establish axis A3. FIG. 7 shows that extension andretraction of second boom piston 105B actuates rotation about axis A3.Rotary encoder R3 measures a current rotational position for second boomsection 104 about axis A3 so as to establish a current directionalbearing B3 about axis A3. Rotary encoder R3 then transmits the currentdirectional bearing B3 in real time to storage, memory and/or a dataprocessing unit as a data element used in overall control of FDU 100.

Rotary encoder R4 within slew drive 800(R4) on FIGS. 13B and 13Cmeasures rotation at axis A4 so as to establish a current directionalbearing B4 at axis A4. FIG. 6 depicts a connection between stinger end104S of second boom section 104 and stinger assembly 600 to establishaxis A4. As shown in more detail on FIGS. 13B and 13C, stinger assembly600 includes slew drive 800(R4) at axis A4. Actuation of slew drive800(R4) at axis A4 is described in detail further below with referenceto FIGS. 13A, 13B and 13C in a separate section of this disclosure.Rotary encoder R4 within slew drive 800(R4) measures a currentrotational position for stinger assembly 600 about axis A4 so as toestablish a current directional bearing B4 about axis A4. Rotary encoderR4 then transmits the current directional bearing B4 in real time tostorage, memory and/or a data processing unit as a data element used inoverall control of FDU 100.

Rotary encoder R5 within slew drive 800(R5) on FIGS. 13B and 13Cmeasures rotation at axis A5 so as to establish a current directionalbearing B5 at axis A5. FIG. 6 depicts axis A5 on stinger assembly 600,where axis A5 is in an orthogonal plane to axis A4. As shown in moredetail on FIGS. 13B and 13C, stinger assembly 600 includes slew drive800(R5) at axis A5. Actuation of slew drive 800(R5) at axis A5 isdescribed in detail further below with reference to FIGS. 13A, 13B and13C in a separate section of this disclosure. Rotary encoder R5 withinslew drive 800(R5) measures a current rotational position for stingerassembly 600 about axis A5 so as to establish a current directionalbearing B5 about axis A5. Rotary encoder R5 then transmits the currentdirectional bearing B5 in real time to storage, memory and/or a dataprocessing unit as a data element used in overall control of FDU 100.

In some embodiments, such as those illustrated on FIG. 7, FDU 100provides first inclinometer I1 deployed, for example, on FDUsuperstructure 101. Suitable embodiments of first inclinometer I1 mayinclude products available from Axiomatic Technologies Corporation ofMississauga, Ontario, Canada, although the scope of this disclosure isnot limited in this regard. First inclinometer I1 is configured tocorrect sets of B_(VAL)[1 . . . 5] for FDU 100 being “out of level”.More specifically, first inclinometer I1 is configured to measure,quantitatively, the degree to which FDU 100 stands “out of level” in itscurrent jobsite position. First inclinometer I1 may send this “out oflevel” information to storage, memory and/or a data processing unit. The“out of level” information from first inclinometer I1 may be used tocorrect current measured bearings values B_(VAL)[1 . . . 5], as measuredby rotary encoders R1 through R5, for corresponding “out of level”variances at axes A1 through A5. In some embodiments, first inclinometerI1 may also be configured to send alarm information when firstinclinometer I1 detects that FDU may be becoming unstable. (i.e.“tipping”).

Exemplary operation and control sequences will now be described to givean understanding of spatial positioning on FDU 100 according topreferred embodiments hereof. In such preferred embodiments, thefollowing operation and control sequences may be initiated and executedusing controller 200 as illustrated on FIGS. 7 and 8. As previouslynoted, however, the scope of this disclosure is not limited to operationand control of FDU 100 using controller 200 embodiments illustrated onFIGS. 7 and 8.

With reference to FIGS. 6 and 7, a user may desire to operate FDU 100with the goal of inserting fluid connection adapter 900 into fluidconnection housing assembly 950 on target wellhead W_(T). The user mayaccomplish this goal, for example, by a combination of: (1) actuatingturret slew drive 110 to rotate turret 102 to set a target azimuth forfluid connection adapter 900 towards fluid connection housing assembly950 on target wellhead W_(T); and (2) actuating first and second boompistons 105A, 105B to elevate/lower and extend/retract fluid connectionadapter 900 along the target azimuth until fluid connection adapter 900is positioned generally above fluid connection housing assembly 950.

Referring now to FIGS. 13A and 13B, for example, the user may nowactuate slew drive 800(R4) at axis A4 and slew drive 800(R5) at axis A5to set fluid connection adapter 900 in a plumb vertical attitudedirectly above fluid connection housing assembly 950. Further smalladjustments to turret slew drive 110 and first and second boom pistons105A, 105B may also assist with setting fluid connection adapter 900 inthe desired plumb vertical attitude.

In some embodiments, such as illustrated on FIG. 7, stinger assemblyprovides second inclinometer I2 on stinger assembly 600. Suitableembodiments of second inclinometer I2 may include products availablefrom Axiomatic Technologies Corporation of Mississauga, Ontario, Canada,although the scope of this disclosure is not limited in this regard.FIG. 14A shows second inclinometer I2 advantageously deployed onnightcap bracket face 1006, for example, although the scope of thisdisclosure is not limited in this regard. In currently preferredembodiments on which second inclinometer I2 is deployed, secondinclinometer I2 is configured to maintain fluid connection adapter 900in a constant plumb vertical attitude during motion of FDU 100. Morespecifically, second inclinometer I2 is configured to measure,quantitatively, the degree to which fluid connection adapter 900 iscurrently “out of plumb vertical” as the user actuates turret slew drive110 and first and second boom pistons 105A, 105B to move fluidconnection adapter 900 towards a desired target. Second inclinometer I2may send this “out of plumb vertical” information to storage, memoryand/or a data processing unit. The “out of plumb vertical” informationfrom second inclinometer I2 may be used to make corresponding automatedadjustments to slew drives 800(R4) and 800(R5) to maintain fluidconnection adapter 900 in a constant plumb vertical attitude regardlessof the current motion of other FDU 100 components. In embodimentsdeploying second inclinometer I2, therefore, the user may, for example,move fluid connection adapter 900 directly above a fluid connectionhousing assembly 950 with fluid connection adapter 900 already set inthe desired plumb vertical attitude.

In other embodiments, second inclinometer I2 may be configured tomaintain fluid connection adapter 900 in a constant attitude other thanplumb vertical. The scope of this disclosure is not limited in thisregard. For example, it may be known that a target wellhead W_(T) is aspecific rotational amount out of plumb vertical along a particularazimuth. In such cases, second inclinometer I2 may be configured tomaintain fluid connection adapter 900 in a corresponding rotationalamount out of plumb vertical along a corresponding azimuth. As a result,insertion of fluid connection adapter 900 into fluid connection housingassembly 950 on target wellhead W_(T) is facilitated.

It will now be appreciated that the current set of directional bearingvalues B_(VAL)[1 . . . 5], as measured by rotary encoders R1 through R5on corresponding axes A1 through A5, represents the current spatialposition of fluid connection adapter 900. In some embodiments, the usermay now instruct FDU 100 to “learn” the current spatial position offluid connection adapter 900 by storing the current set of valuesB_(VAL)[1 . . . 5] for directional bearings B1 through B5 for fluidconnection adapter 900 as currently spatially positioned in a plumbvertical attitude directly above fluid connection housing assembly 950.

The user may then insert fluid connection adapter 900 into fluidconnection housing assembly 950 by making further small adjustments tofirst and second boom pistons 105A, 105B to lower fluid connectionadapter 900 until received in fluid connection housing assembly 950.Fluid connection adapter 900 may then be locked into fluid connectionhousing assembly 950, forming a pressure seal therebetween, and FDU 100may commence fluid delivery to target wellhead W_(T).

When fluid delivery is complete, fluid connection adapter 900 may bereleased from fluid connection housing assembly 950. The user may nowoperate FDU 100 to withdraw fluid connection adapter 900 from currenttarget wellhead W_(T). The user may then, consistent with immediatelyprior disclosure, move fluid connection adapter 900 towards a new targetwellhead W_(T) within range for fluid delivery thereto. Further, alsoconsistent with immediately prior disclosure, the user may instruct FDU100 to “learn” the current spatial position of fluid connection adapter900 at the new target wellhead W_(T) when fluid connection adapter 900is spatially positioned in a plumb vertical attitude directly abovefluid connection housing assembly 950 on the new target wellhead W_(T).

It will thus be appreciated that in preferred embodiments, the user maydirect FDU 100 to “return” to previously-visited target wellheads W_(T),where FDU 100 has previously stored a set of values B_(VAL)[1 . . . 5]for directional bearings B1 through B5 corresponding to fluid connectionadapter 900's spatial position above each of such previously-visitedtarget wellheads W_(T). It will be recalled that FDU 100 is configuredto store and recall sets of B_(VAL)[1 . . . 5], and that FDU 100 isfurther configured to robotically take up a corresponding spatialposition when directed to recall a previously-stored set of B_(VAL)[1 .. . 5]. Thus, the user may direct FDU 100 to “recall” apreviously-stored set of directional bearings values B_(VAL)[1 . . . 5]corresponding to a desired previously-visited target wellhead W_(T).Conventional data processing capability then robotically actuates turretslew drive 110, first and second boom pistons 105A, 105B, and slewdrives 800(R4) and 800(R5) so that FDU 100 robotically takes up thespatial position corresponding to the recalled set of directionalbearings values B_(VAL)[1 . . . 5]. This robotic actuation causes FDU100 to move fluid connection adapter 900 to the previously-storedspatial position above the currently desired (and previously-visited)target wellhead W_(T).

It will be further appreciated that, consistent with the broader scopeof this disclosure, a user may direct FDU 100 to “learn” and then“return” robotically to any desired spatial position within reach. Thescope of this disclosure is not limited in this regard. For example, inanother embodiment discussed further below, the user may instruct FDU100 to take up, robotically, a previously-stored “fold” spatial positionin which FDU 100 is folded for transport.

It will also be understood that the foregoing automated and robotic FDU100 functionality may be embodied on software or firmware executable byconventional data processing architecture including memory, storage andprocessors. Referring momentarily to FIG. 7, such conventional dataprocessing architecture may be deployed/distributed on FDU 100, or oncontroller 200, or elsewhere, and the scope of this disclosure is notlimited to any particular enabling data processing architecture or themanner in which it is deployed on or distributed about FDU 100generally.

This disclosure's description of spatial positioning has been, up tothis point, with reference to currently preferred embodiments asillustrated on FIGS. 6 and 7. As noted above, such currently preferredembodiments include FDU configured with turret 102, first and secondboom sections 103, 104 and stinger assembly 600. Independent rotation ofthese components with respect to one another on illustrated axes ofrotation A1 through A5 allows measured or ordained spatial positioningof hardware located at a distal end of FDU 100. The scope of thisdisclosure is not limited, however, to spatial positioning according tothe currently preferred embodiments illustrated on FIGS. 6 and 7 anddescribed immediately above. The preferred illustrated and describedembodiments herein are exemplary only. It will be appreciated thatconsistent with the more general scope of this disclosure, FDU 100 mayinclude a turret and a stinger assembly separated by a plurality ofconcatenated boom sections S[1 . . . N], in which adjacent boom sectionsare connected via rotatable connections, and where N is a preselectednumber of boom sections according to the desired level ofcontrollability of FDU 100. In such embodiments, (1) each boom sectionhas a turret end and a stinger end; (2) the turret end of boom sectionS[1] is rotatably connected to the turret; (3) the stinger end of oneboom section S[1 . . . N−1] is rotatably connected to the turret end ofan adjacent boom section S[2 . . . N]; and (4) the stinger end of boomsection S[N] is rotatably connected to the stinger assembly.

In such broader embodiments, rotation of the turret defines rotationabout an axis A[1] on a directional bearing B[1]; rotation of the turretend of boom section S[1] about the turret defines rotation about an axisA[2] on a directional bearing B[2]; rotation of the turret end of oneboom section S[2 . . . N] about the stinger end of an adjacent boomsection S[1 . . . N−1] defines rotation about a corresponding axis A[3 .. . N+1] on a corresponding directional bearing B[3 . . . N+1]; androtation of the stinger assembly about the stinger end of boom sectionS[N] defines rotation about an axis A[N+2] on a correspondingdirectional bearing B[N+2].

In further embodiments, again consistent with the more general scope ofthis disclosure, the stinger assembly may be further configured torotate about Q additional rotational axes A[N+3 . . . N+2+Q] each on acorresponding directional bearing B[N+3 . . . N+2+Q]. FDU 100 furtherincludes a plurality of rotary encoders R[1 . . . N+2+Q], one rotaryencoder deployed at each of a corresponding one of axes A[1 . . . N+2+Q]such that each rotary encoder is configured to measure a correspondingone of directional bearings B[1 . . . N+2+Q] to establish sets ofmeasured directional bearings values B_(VAL)[1 . . . N+2+Q], whereinsets of B_(VAL)[1 . . . N+2+Q] define corresponding spatial positionsfor FDU 100. FDU 100 may be configured to store and recall sets ofB_(VAL)[1 . . . N+2+Q], and further configured to robotically take up acorresponding spatial position when directed to recall apreviously-stored set of B_(VAL)[1 . . . N+2+Q]. As described elsewherein greater detail in this disclosure, a slew drive is configured toactuate rotation about at least one of axes A[1 . . . N+2+Q], and apiston is configured to actuate rotation about at least one of axes A[1. . . N+2+Q].

The general scope of this disclosure further includes embodiments inwhich stinger assembly 600 is not configured to rotate about additionalaxes beyond axis A4 as illustrated on FIGS. 6 and 7. In suchembodiments, FDU 100 may include a turret and a stinger assemblyseparated by first and second boom sections in which the boom sectionsare concatenated via a rotatable connection. Each boom section has aturret end and a stinger end, the turret end of the first boom sectionis rotatably connected to the turret; and the stinger end of the secondboom section is rotatably connected to the stinger assembly. Rotation ofthe turret defines rotation about an axis A1 on a directional bearingB1, rotation of the turret end of the first boom section about theturret defines rotation about an axis A2 on a directional bearing B2,rotation of the turret end of the second boom section about the stingerend of the first boom section defines rotation about an axis A3 on acorresponding directional bearing B3, and rotation of the stingerassembly about the stinger end of the second boom section definesrotation about an axis A4 on a corresponding directional bearing B4. Insuch embodiments, FDU 100 further includes a plurality of rotaryencoders R[1 . . . 4], one rotary encoder deployed at each of acorresponding one of axes A[1 . . . 4] such that each rotary encoder isconfigured to measure a corresponding one of directional bearings B[1 .. . 4] to establish sets of measured bearings values B_(VAL)[1 . . . 4].Sets of B_(VAL)[1 . . . 4] define corresponding spatial positions forFDU 100. Similar to embodiments illustrated on FIGS. 6 and 7, FDU 100may be configured to store and recall sets of B_(VAL)[1 . . . 4], andFDU 10 may be further configured to robotically take up a correspondingspatial position when directed to recall a previously-stored set ofB_(VAL)[1 . . . 4].

Referring to the immediately preceding paragraph, it will be furtherappreciated that consistent with the more general scope of thisdisclosure, embodiments of FDU 100 may further include a turret and astinger assembly separated by a plurality of concatenated boom sectionsS[1 . . . N], in which adjacent boom sections are connected viarotatable connections, and where N is a preselected number of boomsections according to the desired level of controllability of FDU 100.In such embodiments, (1) each boom section has a turret end and astinger end; (2) the turret end of boom section S[1] is rotatablyconnected to the turret; and (3) the stinger end of one boom section S[1. . . N−1] is rotatably connected to the turret end of an adjacent boomsection S[2 . . . N].

In such broader embodiments, rotation of the turret defines rotationabout an axis A[1] on a directional bearing B[1]; rotation of the turretend of boom section S[1] about the turret defines rotation about an axisA[2] on a directional bearing B[2]; rotation of the turret end of oneboom section S[2 . . . N] about the stinger end of an adjacent boomsection S[1 . . . N−1] defines rotation about a corresponding axis A[3 .. . N+1] on a corresponding directional bearing B[3 . . . N+1]; androtation of the stinger assembly about the stinger end of boom sectionS[N] defines rotation about an axis A[N+2] on a correspondingdirectional bearing B[N+2].

FDU 100 further includes a plurality of rotary encoders R[1 . . . N+2],one rotary encoder deployed at each of a corresponding one of axes A[1 .. . N+2] such that each rotary encoder is configured to measure acorresponding one of directional bearings B[1 . . . N+2] to establishsets of measured directional bearings values B_(VAL)[1 . . . N+2],wherein sets of B_(VAL)[1 . . . N+2] define corresponding spatialpositions for FDU 100. FDU 100 may be configured to store and recallsets of B_(VAL)[1 . . . N+2], and further configured to robotically takeup a corresponding spatial position when directed to recall apreviously-stored set of B_(VAL)[1 . . . N+2].

Controller 200

As described above with reference to FIG. 7, preferred embodiments ofthe disclosed fluid delivery system include remote control of theoperation of FDU 100. In such embodiments, control is preferably via aremote manual controller 200, in which controller 200 preferablycommunicates with FDU 100 wirelessly via radio frequency communicationRF (although the scope of this disclosure is not limited to suchembodiments and preferences). In illustrated embodiments, controller 200is configured, via wireless communication, to allow a user to performseveral activities, including at least one activity selected from thegroup consisting of: (a) actuating rotation about selected ones of axesA[1 . . . 5]; (b) deploying a nightcap 1000 positioned on the stingerassembly 600; and (c) storing and recalling sets of B_(VAL)[1 . . . 5].

FIG. 8 illustrates a currently preferred embodiment of controller 200.It will be understood that the embodiment of controller 200 depicted onFIG. 8 is exemplary only, and numerous other alternative layouts offeatures and functions are within the scope of this disclosure. It willbe further understood with reference to FIG. 8 that alphanumericreferences on controller 200 such as “A1”, “H2”, “L3”, “D4” are on-boardshort hand notations, marked on controller 200 solely to refer tocorresponding controller operations used in actual operation of FDU 100.Such alphanumerics have no relation, however, to similar part numbersused in this disclosure to indicate items on this disclosure's Figures.Thus, by way of example, “A1” on controller 200 on FIG. 8 refers solelyto an internal controller operation only, and has no relation to thisdisclosure's description above of axis A1 above with reference to FIG.6.

Referring to FIG. 8, the illustrated embodiment of controller 200includes boom joysticks 201, 202 and 203. Controller 200 furtherincludes joystick mode selector 204. Boom joysticks 201, 202, 203 areall active when joystick mode selector 204 is set to MANUAL. Manualjoystick mode allows independent control of rotary motion about each ofaxes A1 through A5 illustrated on FIG. 6. Manual joystick mode thusallows higher skill operators to control movement of FDU 100 entirely bymanual joystick operation.

By contrast, only boom joysticks 201 and 202 are active when joystickmode selector 204 is set to AUTO. In auto joystick mode, operation ofjoysticks 201, 202 switches from rotary motion about axes A1 through A5(per manual joystick mode described immediately above) to an X/Y/Zcoordinate system, or to a left/right, in/out, and up/down commandsystem based on joystick movement. This allows lower skill operators tooperate FDU 100 with more simplicity.

Controller 200 on FIG. 8 further includes nightcap joystick 205 andnightcap enable switch 205A. Nightcap 1000 is described in more detailin this disclosure below with reference to FIGS. 14A, 14B and 14C.Moving nightcap joystick 205 on FIG. 8 to the NIGHTCAP LOCK positionactivates nightcap engage/release mechanism 1008 on FIG. 14C to engageon nightcap engagement pin 1009 when desiring, for example, to pullnightcap 1000 from wellhead W. Engaging on nightcap 1000 does notrequire use of nightcap enable switch 205A on FIG. 8. Moving nightcapjoystick 205 on FIG. 8 to the UNLOCK NIGHTCAP position, however, alsorequires simultaneous pushing of nightcap enable switch 205A (on leftside of controller 200) in order to activate nightcap engage/releasemechanism 1008 on FIG. 14C to release nightcap engagement pin 1009. Thisfeature enhances safe removal of nightcap 1000 from nightcapengage/release mechanism 1008 on FIG. 14C by reducing chances of anaccidental nightcap release, for example.

As described above with reference to FIGS. 6 and 7, currently preferredembodiments of FDU 100 include a feature that allows FDU 100 to “learn”a desired spatial position by storing a set of measured values B_(VAL)[1. . . 5] for directional bearings B1 through B5 on corresponding axes A1through A5 (refer FIG. 6) where the set of measured directional bearingvalues B_(VAL)[1 . . . 5] represents the “learned” spatial position.Such “learned” spatial positions may include, for example, FDU 100'sspatial position when delivering fluid to a selected wellhead. Memorywithin controller 200 may store sets of measured values B_(VAL)[1 . . .5] for directional bearings B1 through B5 corresponding to such“learned” spatial positions. FDU 100 may then, for example, return tothe selected wellhead by retrieving the set of directional bearingsvalues B_(VAL)[1 . . . 5] from controller 200's memory corresponding tothe previously-stored spatial position for the wellhead.

FIG. 8 illustrates controller 200 including stored position selector 206for selecting a desired FDU 100 spatial position to be addressed. Up to12 (twelve) previously-stored positions may be stored in memory in theembodiment of controller 200 depicted on FIG. 8. The scope of thisdisclosure is not limited in this regard, however.

To store a current FDU 100 spatial position, stored position selector206 is turned to select the memory location in which the current FDU 100spatial position is desired to be stored. Pushing memory activate switch206A (on left side of controller 200) simultaneously with pushing storeactivate switch 206B (on right side of controller 200) will causecontroller 200 to store the current FDU 100 spatial position in theselected memory location.

To recall a previously-stored FDU 100 spatial position, stored positionselector 206 is turned to select the memory location in which thedesired previously-stored FDU 100 spatial position stored. Pushingmemory activate switch 206A (on left side of controller 200)simultaneously with pushing recall activate switch 206C (on right sideof controller 200) causes FDU 100 to move robotically to return to thespatial position previously stored in the selected memory location. As asafety precaution, FDU 100 advantageously moves only so long as both thememory activate switch 206A and the recall activate switch 206C arebeing actively pushed concurrently. Robotic FDU 100 motion stops ifeither switch is released. Controller 200 advantageously also performsadditional safety checks prior to moving FDU 100 automatically, such aschecking boom height and clearance.

FIG. 8 illustrates controller 200 further including fold mode selectors207A and 207B. Controller 200's memory also stores a preset “fold”spatial position in which FDU 100 is folded for transport. Activatingfold mode selectors 207A and 207B simultaneously moves FDU 100robotically the preset “fold” spatial position. Again, as a safetyprecaution, FDU 100 advantageously moves only so long as both fold modeselectors 207A and 207B are activated. Robotic FDU 100 motion stops ifeither of fold mode selectors 207A or 207B is deactivated.

FIG. 8 illustrates controller 200 further including emergency stopactivator 208. Activating emergency stop activator 208 causes allcurrent motion of FDU 100 to stop immediately, and disables all furtherFDU 100 motion until emergency stop activator is affirmativelydeactivated or reset.

Stinger Assembly 600 (and Actuation of Rotation Thereof about SecondBoom Section 104)

As described above, FIG. 6 depicts stinger assembly 600 connected tostinger end 104S of second boom section 104 via a rotating connection.FIG. 6 further depicts fluid connection adapter 900 deployed on stingerassembly 600. As shown on FIG. 6, the rotating connection betweenstinger end 104S of second boom section 104 and stinger assembly 600 isat axis A4. As further shown on FIG. 6, stinger assembly 600 alsoprovides rotation about axis A5, where rotation about axis A5 is in anorthogonal plane to rotation about axis A4. FIGS. 13A, 13B and 13Cillustrate currently preferred embodiments of stinger assembly 600 indetail. FIG. 13A is general arrangement view of assembled stingerassembly 600. FIG. 13B is a section as shown on FIG. 13A, and FIG. 13Cis an exploded view of FIG. 13A. FIGS. 13A, 13B and 13C also illustratenightcap 1000 generally. Nightcap 1000 is described in detail below withreference to FIGS. 14A, 14B and 14C in a separate section of thisdisclosure.

Looking at FIGS. 13A, 13B and 13C together, swivel joint embodiment 500Bis rigidly connected to stinger end 104S of second boom section 104 viaboom flange 150. In preferred embodiments, boom flange may be welded tosecond boom section 104, although the scope of this disclosure is notlimited to any particular rigid connection of boom flange 150 to secondboom section 104. Boom flange 150 is further preferably attached toswivel joint 500B via fastener attachment to first housing piece 523. Insome embodiments, boom flange 150 may share fasteners 527 with firsthousing piece 523.

FIGS. 13A, 13B and 13C further show first elbow of swivel jointembodiment 500B rigidly connected to delivery piping 120 via unionassembly 300, all as described above more generally with reference toFIGS. 12A through 12C. Swivel joint 500B on FIGS. 13A through 13C alsoincludes clamp assembly 400 for rigid connection with second elbow 536,all again as described above more generally with reference to FIGS. 12Athrough 12C.

FIGS. 13A, 13B and 13C further show first elbow 501 of swivel jointembodiment 500A rigidly connected to swivel embodiment 500B. It will beappreciated that in the preferred embodiments illustrated on FIGS. 13Athrough 13C, second elbow 536 on swivel joint 500B and first elbow 501on swivel joint 500A are the same fitting, obviating the need forconnection pipe between swivel joints 500A, 500B. The scope of thisdisclosure is not limited in this regard, however. Second elbow 508 onswivel joint 500A is rigidly connected to fluid connection adapter 900,preferably via union assembly 300 as described above more generally withreference to FIGS. 11A through 11C.

FIGS. 13B and 13C show slew drive 800(R4) deployed on swivel jointembodiment 500B and slew drive 800(R5) deployed on swivel jointembodiment 500A. Slew drives 800(R4) and 800(R5) are conventional inpreferred embodiments. FIG. 13C shows slew drives 800(R4) and 800(R5)each including a fixed portion 801, and a rotating portion 802 driven byworm drive 803. Worm drives 803 each include a rotary encoder (R4 andR5) respectively. In more detail, worm drives 803 each include ahydraulically-driven worm gear motor plus a rotary encoder on board. Therotary encoder may measure current rotary displacement or set a desiredrotary displacement corresponding to directional bearings B4 or B5, asapplicable. Suitable embodiments of slew drives 800(R4) and 800(R5) mayinclude products available from Cone Drive Operations, Inc. of TraverseCity, Mich., U.S.A., although the scope of this disclosure is notlimited in this regard. It will also be appreciated that the scope ofthis disclosure is not limited to use of slew drives. The scope of thisdisclosure also includes non-illustrated embodiments in which rotationat axes A1, A4 and A5 is driven by hydraulic motors, hydraulic pistonsassemblies, and the like.

FIGS. 13A, 13B and 13C thus illustrate, with additional reference toFIG. 6, that in currently preferred embodiments, rotation of swiveljoint embodiment 500B by slew drive 800(R4) enables rotation of stingerassembly 600 about axis A4. In illustrated embodiments, fixed portion801 on slew drive 800(R4) connects rigidly to second housing piece 526of swivel joint 500B via conventional fasteners, for example. Rotatingportion 802 on slew drive 800(R4) connects rigidly to clamp assembly 400via bracket 810. Conventional fasteners may connect rotating portion 802to bracket 810, and connect bracket 810 to clamp assembly 400. In someembodiments, bracket 810 may share fasteners 408 with clamp assembly400. Worm drive 803 on slew drive 800(R4) thus rotates integral pin 525and second elbow 536 on swivel joint 500B via connection of rotatingportion 802 to clamp assembly 400. Rotary encoder R4, deployed inassociation with worm drive 803, measures a current rotational positionfor swivel joint 500B about axis A4 so as to establish a currentdirectional bearing B4 about axis A4. Rotary encoder R4 then transmitsthe current directional bearing B4 in real time to storage, memoryand/or a data processing unit as a data element used in overall controlof FDU 100.

FIGS. 13A, 13B and 13C further illustrate, with additional reference toFIG. 6, that in currently preferred embodiments, rotation of swiveljoint embodiment 500A by slew drive 800(R5) enables rotation of stingerassembly 600 about axis A5. In illustrated embodiments, fixed portion801 on slew drive 800(R5) connects rigidly to second housing piece 506of swivel joint 500A via conventional fasteners, for example. Rotatingportion 802 on slew drive 800(R5) connects rigidly to nightcap bracketflange 1007 on nightcap bracket 1005. In preferred embodiments, nightcapbracket 1005 attaches to second elbow 508 on swivel joint 500A. Suchattachment may be via conventional fasteners threaded into bossesprovided in the exterior wall of second elbow 508, as illustrated onFIG. 13A, for example. The scope of this disclosure is not limited inthis regard. Worm drive 803 on slew drive 800(R5) thus rotates swivelcollet 505 and second elbow 508 on swivel joint 500A via connection ofrotating portion 802 ultimately to second elbow 508. Rotary encoder R5,deployed in association with worm drive 803, measures a currentrotational position for swivel joint 500A about axis A5 so as toestablish a current directional bearing B5 about axis A5. Rotary encoderR5 then transmits the current directional bearing B5 in real time tostorage, memory and/or a data processing unit as a data element used inoverall control of FDU 100.

Nightcap 1000

FIGS. 14A, 14B and 14C illustrate a currently preferred embodiment ofnightcap 1000 and its associated features, plus the deployment andoperation thereof. Embodiments of nightcap 1000 described in thisdisclosure should be considered optional in conjunction with embodimentsof FDU 100 herein. The scope of this disclosure is not limited as towhether or not FDU 100 embodiments include embodiments of nightcap 1000.

FIG. 14A illustrates nightcap 1000 positioned longitudinally opposed tofluid connection adapter 900 on stinger assembly 600. While preferredembodiments position nightcap 1000 longitudinally opposed to fluidconnection adapter 900, the scope of this disclosure is not limited inthis regard. Nightcap engage/release mechanism 1008 includes anengagement receptacle for holding nightcap 1000 by nightcap engagementpin 1009 (engagement receptacle not specifically illustrated, refer FIG.14C for nightcap engagement pin 1009). FIG. 14A shows nightcapengage/release mechanism 1008 deployed within nightcap bracket 1005. Inpreferred embodiments, nightcap bracket 1005 attaches to second elbow508 on swivel joint embodiment 500A at axis A5 (refer momentarily toFIG. 6). Such attachment may be as illustrated on FIG. 14B, byconventional fasteners threaded into bosses provided in the exteriorwall of second elbow 508. The scope of this disclosure is not limited inthis regard. FIG. 13C illustrates preferred embodiments of nightcapbracket 1005 also including nightcap bracket flange 1007 for fastenerattachment to rotating portion 802 of slew drive 800(R5) at axis A5.Such flange attachment is also shown on FIGS. 14A, 14B and 14C but notcalled out by part number. Such flange attachment strengthens nightcapbracket 1005's overall attachment.

It will be further appreciated from FIGS. 14A, 14B and 14C that nightcap1000 and fluid connection adapter 900 are similar in that both areconfigured to be received and remotely locked into fluid connectionhousing assembly 950. Refer above to FIG. 4 and associated disclosurefor discussion of preferred embodiments of fluid connection adapter 900and fluid connection housing assembly 950. Refer also, for example, toco-pending, commonly assigned U.S. Nonprovisional Patent Application“Remotely Operated Fluid Connection And Seal”, Ser. No. 16/221,279(referred to herein as the “'279 Disclosure”). The '279 Disclosure isincorporated herein by reference. The following description of nightcap1000 and fluid connection adapter 900 generally follows and isconsistent with the disclosure of FIGS. 3 and 4 of the '279 Disclosure,and paragraphs 0048 and 0049 of the '279 Disclosure. Nightcap 1000 andfluid connection adapter 900 are alternative adapter embodiments. Fluidconnection adapter 900 provides an open connection to enable flow into(or out of) the wellhead W when fluid connection adapter 900 is receivedinto fluid connection housing assembly 950. By contrast, nightcap 1000provides a blank or closed-off end to enable temporary closure of thewellhead W while nightcap 1000 is received into fluid connection housingassembly 950. It will thus be appreciated from FIGS. 14A, 14B and 14Cthat nightcap 1000 and fluid connection adapter 900 each share a commonconfiguration at the distal ends thereof (the distal ends to be receivedinto fluid connection housing assembly 950). In this way, such commonconfiguration allows nightcap 1000 and fluid connection adapter 900 tobe interchangeable when received into fluid connection housing assembly950. It will be further appreciated from reference to FIG. 4 andassociated disclosure that nightcap 1000 and fluid connection adapter900 preferably each share a common configuration from among embodimentsdisclosed in the Preferred Fluid Connection Designs (as that term isdefined above with reference to FIG. 4), although the scope of thisdisclosure is not limited to the common configuration that nightcap 1000and fluid connection adapter 900 might share.

FIGS. 14A, 14B and 14C also illustrate deployment and operation ofnightcap 1000. As described above, FIG. 14A depicts, in preferredembodiments, nightcap 1000 positioned longitudinally opposed to fluidconnection adapter 900. In such embodiments, nightcap 1000 assumes arest position pointing generally upwards while fluid connection adapter900 points generally downwards during fluid delivery mode. When nightcap1000 is desired to be deployed at a selected wellhead, the arrow on FIG.14B shows that slew drive 800(R5) at axis A5 may be operated to rotatenightcap bracket 1005 so that nightcap 1000 and fluid connection adapter900 are inverted. Thus, consistent with FIG. 14B, rotation of nightcapbracket 1005 brings nightcap 1000 into position to be inserted intofluid connection housing assembly 950 on a selected wellhead.

FIG. 14C depicts nightcap 1000 previously brought to a selected wellheadW and inserted and locked into fluid connection housing assembly 950 onthe selected wellhead W. In preferred embodiments, such insertion andlocking may be according to corresponding disclosure in the '279Disclosure, incorporated herein by reference. Nightcap engage/releasemechanism 1008 may then be actuated to release nightcap bracket 1005from nightcap 1000 by releasing nightcap engagement pin 1009 from theengagement receptacle within nightcap engage/release mechanism 1008. Asshown by the arrow on FIG. 14C, once nightcap bracket 1005 is releasedfrom nightcap 1000, nightcap bracket 1005 may be raised from nightcap1000. As described elsewhere in this disclosure, nightcap engage/releasemechanism 1008 is preferably actuated remotely from controller 200(refer FIGS. 7 and 8 herein and associated disclosure, for example),although the scope of this disclosure is not limited to remote actuationof nightcap engage/release mechanism 1008.

Although not specifically illustrated herein, engagement and pickup ofnightcap 1000 from fluid connection housing assembly 950 at a selectedwellhead is generally the reverse operation to its deployment asdescribed immediately above. Nightcap bracket 1005 may be brought downonto nightcap 1000 so that nightcap engagement pin 1009 is received intothe engagement receptacle within nightcap engage/release mechanism 1008.Nightcap engage/release mechanism 1008 may then be actuated to engagenightcap engagement pin 1009. Nightcap 1000 may then be unlocked andreleased from fluid connection housing assembly 950. In preferredembodiments, such unlocking and release from fluid connection housingassembly 950 may be according to corresponding disclosure in the '279Disclosure, incorporated herein by reference. Once nightcap 1000 isunlocked and released from fluid connection housing assembly 950,nightcap bracket 1005 may be raised from fluid connection housingassembly 950 with nightcap 1000 attached. Nightcap engage/releasemechanism 1008 is again preferably actuated remotely from controller 200(refer FIGS. 7 and 8 herein and associated disclosure, for example),although the scope of this disclosure is not limited to remote actuationof nightcap engage/release mechanism 1008.

Wall Thickness Monitoring of Fluid-Bearing Pipe and Fittings

It will be appreciated that services and applications for which FDU 100is designed include delivery of fluids that may be abrasive or corrosiveto delivery pipe and fittings. Just by way of example, fracking fluidsknown in the art may contain solids that cause internal abrasion todelivery pipe and fittings when delivered at operational deliverypressures and volumes (speeds). Further, fracking fluids known in theart may contain ingredients that while beneficial to frackingoperations, may also be internally corrosive to delivery pipe andfittings.

In such services and applications, therefore, it is advantageous tomonitor wall thickness of delivery piping and fittings in selectedregions and locations, where such selected regions and locations are atrisk of loss of wall thickness during service. Preferably, such wallthickness monitoring is in real time, although the scope of thisdisclosure is not limited in this regard.

FIG. 15 is a schematic generally illustrating wall thickness monitoringaccording to this disclosure. FIG. 15 depicts a section throughfluid-bearing pipe or fitting 700. The schematic of FIG. 15 illustratesfluid-bearing pipe or fitting 700 generically with exemplary depictionof a conventional elbow fitting. However, the use of an elbow fitting onFIG. 15 is exemplary only, and fluid-bearing pipe or fitting 700 may beany fluid-bearing fitting or length of fluid-bearing pipe, and the scopeof this disclosure is not limited in this regard.

FIG. 15 further illustrates fluid flow vectors V within fluid bearingpipe or fitting 700. The schematic of FIG. 15 uses a convention in whichfluid flow vectors V depict expected directions of flow, and in whichlarger fluid flow vectors V represent expected areas of faster flow. Theoverall fluid flow pattern depicted by fluid flow vectors V on FIG. 15would be expected by those of ordinary skill in the art, in that, atleast with respect to the depicted elbow fitting, faster flow isexpected near the inside turn and then towards the outside inner wall.

As noted above, faster flow of abrasive or corrosive fluids (such ascommonly seen in fracking operations, for example) suggests that, atleast with respect to the elbow fitting depicted on FIG. 15, wallthickness of the fitting may be expected to be at risk of loss near theinside turn and on the outside inner wall after the turn. FIG. 15depicts wall thickness sensors 750 deployed on the outside offluid-bearing pipe or fitting 700 at these locations. Wall thicknesssensors 750 are conventional, and may send wall thickness informationperiodically to conventional data processing equipment such as computersor digital monitors. Such data processing equipment may alert users thatthe wall thickness at the sensed locations has been lost to a pointwhere fluid-bearing pipe or fitting 700 no longer has sufficient wallthickness to carry fluid safely at desired operating pressures andflows. Suitable embodiments of wall thickness sensors 750 may includeproducts available from Dakota Ultrasonics Corporation of Scotts Valley,Calif., U.S.A., although the scope of this disclosure is not limited inthis regard.

In other embodiments, this disclosure further describes a method fordelivering fluid, the method comprising the steps of:

(a) providing a fluid delivery unit (FDU), comprising: a turret and astinger assembly separated by first and second boom sections in whichthe boom sections are concatenated via a rotatable connection; a fluidinlet; a fluid connection adapter deployed on the stinger assembly; anda plurality of swivel joints, wherein the fluid inlet, the swivel jointsand the fluid connection adapter are in fluid flow communication along aFDU fluid pathway; wherein: (1) each boom section has a turret end and astinger end; (2) the turret end of the first boom section is rotatablyconnected to the turret; and (3) the stinger end of the second boomsection is rotatably connected to the stinger assembly; wherein rotationof the turret defines rotation about an axis A1 on a directional bearingB1; wherein rotation of the turret end of the first boom section aboutthe turret defines rotation about an axis A2 on a directional bearingB2; wherein rotation of the turret end of the second boom section aboutthe stinger end of the first boom section defines rotation about an axisA3 on a corresponding directional bearing B3; wherein rotation of thestinger assembly about the stinger end of the second boom sectiondefines rotation about an axis A4 on a corresponding directional bearingB4; wherein the stinger assembly is further configured to rotate aboutan axis A5 on a corresponding directional bearing B5; wherein the FDUfurther includes a plurality of rotary encoders R[1 . . . 5], one rotaryencoder deployed at each of a corresponding one of axes A[1 . . . 5]such that each rotary encoder is configured to measure a correspondingone of directional bearings B[1 . . . 5] to establish sets of measuredbearings values B_(VAL)[1 . . . 5];

(b) selectively moving ones of the turret, the boom sections and thestinger assembly to position the FDU in a first selected spatialposition relative to a first fluid connection housing assembly;

(c) storing a first set of B_(VAL)[1 . . . 5] corresponding to the firstspatial position;

(d) connecting the fluid connection adapter to the first fluidconnection housing assembly;

(e) commencing fluid flow to the fluid inlet such that fluid flows intothe first fluid connection assembly via the FDU fluid pathway;

(f) terminating fluid flow to the fluid inlet;

(g) disconnecting the fluid connection adapter from the first fluidconnection housing assembly;

(h) selectively moving ones of the turret, the boom sections and thestinger assembly to position the FDU in a second selected spatialposition; and

(i) recalling the first set of B_(VAL)[1 . . . 5]; wherein responsive tostep (i), the FDU moves robotically to return the first spatialposition.

In some method embodiments, each swivel joint may have an internaldiameter of not less than about 7 inches, and each swivel joint may befurther capable of retaining an internal pressure of not less than about7,500 psi. In such method embodiments, each swivel joint may be furthercapable of rotation while retaining an internal pressure of not lessthan about 7,500 psi. In such method embodiments, step (e) preferablyincludes commencing fluid flow to the fluid inlet at a fluid pressurenot less than about 7,500 psi.

In other method embodiments, each swivel joint may have an internaldiameter of not less than about 7 inches, and each swivel joint may befurther capable of retaining an internal pressure of not less than about10,000 psi. In such method embodiments, each swivel joint may be furthercapable of rotation while retaining an internal pressure of not lessthan about 10,000 psi. In such method embodiments, step (e) preferablyincludes commencing fluid flow to the fluid inlet at a fluid pressurenot less than about 10,000 psi.

In other method embodiments, each swivel joint may have an internaldiameter of not less than about 7 inches, and each swivel joint may befurther capable of retaining an internal pressure of not less than about15,000 psi. In such embodiments, each swivel joint may be furthercapable of rotation while retaining an internal pressure of not lessthan about 15,000 psi. In such method embodiments, step (e) preferablyincludes commencing fluid flow to the fluid inlet at a fluid pressurenot less than about 15,000 psi.

Although the material in this disclosure has been described in detailalong with some of its technical advantages, it will be understood thatvarious changes, substitutions and alternations may be made to thedetailed embodiments without departing from the broader spirit and scopeof such material as set forth in the following claims.

1. (canceled)
 2. A spatially positioned assembly, comprising: a fluidinlet in fluid flow communication with a fluid connection adapter; aturret; a plurality of concatenated boom sections S[1 . . . N] in whicheach boom section has a proximal end and a distal end, wherein theproximal end of boom section S[1] is rotatably connected to the turret,wherein the distal end of one boom section S[1 . . . N−1] is rotatablyconnected to the proximal end of an adjacent boom section S[2 . . . N]and the distal end of boom section S[N] is rotatably connected with thefluid connection adapter; wherein rotation of the turret definesrotation about an axis A[1] on a directional bearing B[1]; whereinrotation of the proximal end of boom section S[1] about the turretdefines rotation about an axis A[2] on a directional bearing B[2];wherein rotation of the proximal end of one boom section S[2 . . . N]about the distal end of an adjacent boom section S[1 . . . N−1] definesrotation about a corresponding axis A[3 . . . N+1] on a correspondingdirectional bearing B[3 . . . N+1]; wherein rotation of the fluidconnection adapter about the distal end of boom section S[N] in at leastone axis defines rotation about an axis A[N+2] on a correspondingdirectional bearing B[N+2]; and wherein the spatially positionedassembly further includes a plurality of axis position measuring devicesR[1 . . . N+2], one axis position measuring device deployed at each of acorresponding one of axes A[1 . . . N+2] such that each axis positionmeasuring device is configured to measure a corresponding one ofdirectional bearings B[1 . . . N+2] to establish measured directionalbearings values B_(VAL)[1 . . . N+2], wherein B_(VAL)[1 . . . N+2]contribute to defining corresponding spatial positions for the spatiallypositioned assembly.
 3. The spatially positioned assembly of claim 2, inwhich the spatially positioned assembly is configured to display datafrom at least one measured directional bearing value from among currentB_(VAL)[1 . . . N+2], wherein current B_(VAL)[1 . . . N+2] correspond toa current spatial position of the spatially positioned assembly.
 4. Thespatially positioned assembly of claim 2, in which processing ofmeasured directional bearing values from among B_(VAL)[1 . . . N+2]enables the spatially positioned assembly to maintain the fluidconnection adapter in a constant plumb vertical attitude during motionof the spatially positioned assembly.
 5. The spatially positionedassembly of claim 3, in which processing of measured directional bearingvalues from among B_(VAL)[1 . . . N+2] enables the spatially positionedassembly to maintain the fluid connection adapter in a constant plumbvertical attitude during motion of the spatially positioned assembly. 6.The spatially positioned assembly of claim 2, in which the spatiallypositioned assembly is configured to store and recall sets of measureddirectional values from among B_(VAL)[1 . . . N+2].
 7. The spatiallypositioned assembly of claim 6, in which the spatially positionedassembly is further configured to robotically take up a correspondingspatial position when directed to recall a set of measured directionalbearing values from among previously-stored B_(VAL)[1 . . . N+2].
 8. Thespatially positioned assembly of claim 2, in which at least one of theplurality of axis position measuring devices R[1 . . . N+2] is a rotaryencoder.
 9. A spatially positioned assembly, comprising: a fluid inletin fluid flow communication with a fluid connection adapter; a turretrotatably connected to a superstructure via a first rotatableconnection: at least one boom section S[1 . . . N] in which N≥1, whereineach boom section has a proximal end and a distal end, wherein theproximal end of boom section S[1] is rotatably connected to the turretvia a second rotatable connection, wherein the distal end of boomsection S[N] is rotatably connected with the fluid connection adaptervia a final rotatable connection; wherein further, if N>1, the distalend of one boom section S[ . . . N−1] is connected to the proximal endof an adjacent boom section S[2 . . . N] via corresponding intermediateconnections positioned between the second rotatable connection and thefinal rotatable connection in which X selected ones of the intermediateconnections (wherein N≥X≥0) are measured intermediate rotatableconnections; and wherein the spatially positioned assembly furtherincludes a plurality of axis position measuring devices R[1 . . . X+3],one axis position measuring device deployed at each of a correspondingone of the first rotatable connection, the second rotatable connection,the measured intermediate rotatable connections and the final rotatableconnection, wherein each axis position measuring device R[1 . . . X+3]is configured to measure a corresponding one of directional bearings B[1. . . X+3] on each of the first rotatable connection, the secondrotatable connection, the measured intermediate rotatable connections(if N>1) and the final rotatable connection such that measureddirectional bearings values B_(VAL)[1 . . . X+3] contribute to definingcorresponding spatial positions for the spatially positioned assembly.10. The spatially positioned assembly of claim 9, in which the spatiallypositioned assembly is configured to display data from at least onemeasured directional bearing value from among current B_(VAL)[1 . . .X+3], wherein current B_(VAL)[1 . . . X+3] correspond to a currentspatial position of the spatially positioned assembly.
 11. The spatiallypositioned assembly of claim 9, in which processing of measureddirectional bearing values from among B_(VAL)[1 . . . X+3] enables thespatially positioned assembly to maintain the fluid connection adapterin a constant plumb vertical attitude during motion of the spatiallypositioned assembly.
 12. The spatially positioned assembly of claim 10,in which processing of measured directional bearing values from amongB_(VAL)[1 . . . X+3] enables the spatially positioned assembly tomaintain the fluid connection adapter in a constant plumb verticalattitude during motion of the spatially positioned assembly.
 13. Thespatially positioned assembly of claim 9, in which the spatiallypositioned assembly is configured to store and recall sets of measureddirectional values from among B_(VAL)[1 . . . X+3].
 14. The spatiallypositioned assembly of claim 13, in which the spatially positionedassembly is further configured to robotically take up a correspondingspatial position when directed to recall a set of measured directionalbearing values from among previously-stored B_(VAL)[1 . . . X+3]. 15.The spatially positioned assembly of claim 9, in which at least one ofthe plurality of axis position measuring devices R[1 . . . X+3] is arotary encoder.
 16. A spatially positioned assembly, comprising: a fluidinlet in fluid flow communication with a fluid connection adapter; atleast one boom section S[1 . . . N] in which N≥1, wherein each boomsection has a proximal end and a distal end, wherein the proximal end ofboom section S[1] is connected with a superstructure via a firstconnection, wherein the distal end of boom section S[N] is connectedwith the fluid connection adapter via a final connection; whereinfurther, if N>1, the distal end of one boom section S[1 . . . N−1] isconnected to the proximal end of an adjacent boom section S[2 . . . N]via corresponding intermediate connections positioned between the firstconnection and the final connection in which Y selected ones (wherein(N+1)≥Y≥2) of the first connection, the intermediate connections (ifN>1) and the final connection are measured rotatable connections; andwherein the spatially positioned assembly further includes a pluralityof axis position measuring devices R[1 . . . Y], one axis positionmeasuring device deployed at each of a corresponding one of the measuredrotatable connections, wherein each axis position measuring device R[1 .. . Y] is configured to measure a corresponding one of directionalbearings B[1 . . . Y] on each of the measured rotatable connections suchthat measured directional bearings values B_(VAL)[1 . . . Y] contributeto defining corresponding spatial positions for the spatially positionedassembly.
 17. The spatially positioned assembly of claim 16, in whichthe spatially positioned assembly is configured to display data from atleast one measured directional bearing value from among current B_(VAL)[. . . Y] wherein current B_(VAL)[1 . . . Y] correspond to a currentspatial position of the spatially positioned assembly.
 18. The spatiallypositioned assembly of claim 16, in which processing of measureddirectional bearing values from among B_(VAL)[1 . . . Y] enables thespatially positioned assembly to maintain the fluid connection adapterin a constant plumb vertical attitude during motion of the spatiallypositioned assembly.
 19. The spatially positioned assembly of claim 18,in which said processing of measured directional bearing values is inconjunction with data from at least one inclinometer.
 20. The spatiallypositioned assembly of claim 17, in which processing of measureddirectional bearing values from among B_(VAL)[1 . . . Y] enables thespatially positioned assembly to maintain the fluid connection adapterin a constant plumb vertical attitude during motion of the spatiallypositioned assembly.
 21. The spatially positioned assembly of claim 16,in which the spatially positioned assembly is configured to store andrecall sets of measured directional values from among B_(VAL)[1 . . .Y].
 22. The spatially positioned assembly of claim 21, in which thespatially positioned assembly is further configured to robotically takeup a corresponding spatial position when directed to recall a set ofmeasured directional bearing values from among previously-storedB_(VAL)[1 . . . Y].
 23. The spatially positioned assembly of claim 1, inwhich at least one of the plurality of axis position measuring devicesR[1 . . . Y] is a rotary encoder.
 24. A spatially positioned assembly,comprising: a fluid inlet in fluid flow communication with a fluidconnection adapter; a turret; a plurality of concatenated boom sectionS[1 . . . N] in which each boom section has a proximal end and a distalend, wherein the proximal end of boom section S[1] is rotatablyconnected to the turret, wherein the distal end of one boom section S[1. . . N−1] is rotatably connected to the proximal end of an adjacentboom section S[2 . . . N] and the distal end of boom section S[N] isrotatably connected with the fluid connection adapter; wherein rotationof the turret defines rotation about an axis A[1]; wherein rotation ofthe proximal end of boom section S[1] about the turret defines rotationabout an axis A[2]; wherein rotation of the proximal end of one boomsection S[2 . . . N] about the distal end of an adjacent boom sectionS[1 . . . N−1] defines rotation about a corresponding axis A[3 . . .N+I]; wherein rotation of the fluid connection adapter about the distalend of boom section S[N] in at least one axis defines rotation about anaxis A[N+2]; and wherein operator control over rotation about axes A[1 .. . N+2] establishes corresponding desired spatial positions for thespatially positioned assembly.
 25. The spatially positioned assembly ofclaim 24, in which N=2.
 26. The spatially positioned assembly of claim24, in which the distal end of boom section S[N] is rotatably connectedwith the fluid connection adapter via Q independently rotatable axesA[N+2 . . . N+1+Q] wherein Q≥2, and in which operator control overrotation about axes A[1 . . . N+1+Q] establishes corresponding desiredspatial positions for the spatially positioned assembly.
 27. Thespatially positioned assembly of claim 25, in which the distal end ofboom section S[2] is rotatably connected with the fluid connectionadapter via Q independently rotatable axes A[4 . . . Q+3] wherein Q≥2,and in which operator control over rotation about axes A[1 . . . 5]establishes corresponding desired spatial positions for the spatiallypositioned assembly.
 28. The spatially positioned assembly of claim 27,in which Q=2 such that the distal end of boom section S[2] is rotatablyconnected with the fluid connection adapter via two independentlyrotatable axes A[4 . . . 5], and in which operator control over rotationabout axes A[1 . . . 5] establishes corresponding desired spatialpositions for the spatially positioned assembly.
 29. The spatiallypositioned assembly of claim 24, in which at least one swivel joint isinterposed in fluid communication between the fluid inlet and the fluidconnection adapter.
 30. The spatially positioned assembly of claim 29,in which each swivel joint has an internal diameter of not less thanabout 7 inches, and in which each swivel joint is further capable ofrotation while retaining an internal pressure of not less than about10,000 psi.
 31. The spatially positioned assembly of claim 24, in whicha selected one of (a) a slew drive and (b) a piston is configured toactuate rotation about at least one of axes A[1 . . . N+2].